ZEST BOLT Service Manual

ENGINE 1.3 QUADRAJET (75PS) 44 47.Position the crankcase sump (1a) in its housing and secure it tightening the M6 bolt s (1b) to a torque of 0.8 ~ 1.0 Kg-m and the M6 nust (1c) to a torque of 0.8 ~ 1.0 Kg-m. NOTE : Follow the order shown in the figure for each tightening sequence. The tightening to 0.8 - 1.0 Kg-m is performed in two stages: pre tightening to 0.4 Kg-m followed by an additional tightening of 0.8 - 1.0 Kg-m. 48.Place the bracket (2a) in its housing and secure it by tightening the M8 bolts (2b) to a torque of 2.7 ~ 3.3 Kg-m. 49.Rotate the engine through 180° on the overhaul stand. 50.Place the engine oil dip stick pipe back in it s housing and fasten it with the bolt. 51.Close the oil vapour pipe retaining clip. 52.Place the intermediate driveshaft mount in position and secure it tightening the M8 bolts to a torque of 2.0 ~ 2.4 Kg-m. 53.Remove the tool 287158900651 (Hose). 54.Place the timing side rigid engine support in its housing with the engine lift bracket and secure it tightening the M10 bolts to a torque of 5.7 ~ 6.3 Kg-m . 55.Place the water pump, complete with gasket in position, and then tighten the M10 bolst to a 0.8 ~ 1.0 Kg-m torque. 56.Position the engine components single belt moving tensioner in its housing and secure it tightening the M10 bolt to a torque of 4.5 ~ 5.5 Kg-m . 57.Position the auxiliary drive belt fixed tensioner in its housing and secure it tightening the M8 bolt to a torque of 2.2 ~ 2.7 Kg-m . 58.Adjust the mobile tensioner with a wrench and fit the auxiliary drive belt. 59.Place the turbocharger unit complete with caat lytic converter back in it s housing and secure it by tightening the M8 nuts to a torque of 2.2 ~ 2.7 Kg- m . 60.Refit the exhaust manifold heat shield with the engine lift bracket and secure with the nut and bolts. 61.Position the pipe carrying engine oil to the turbocharger in its housing and secure it tightening M10 connectors to a torque of 1.3 ~ 1.6 Kg-m. NOTE : Follow the order shown in the figure for each tightening sequence. The tightening to 0.8 - 1.0 Kg-m is performed in two stages: pre tightening to 0.4 Kg-m followed by an additional tightening of 0.8 - 1.0 Kg-m 62. Position a new gasket between the crankcase and the engine oil return pipe to the turbocharger. 63.Position a new gasket between the crankcase and the engine oil return pipe to the turbocharger. 64.Fit the protective strip s to the oil filter and the engine oil heat exchanger. 65.Place the electrical wiring in position and fasten it to the bands on the air capacity chamber. 66.Connect the electrical connection to the E.G .R. solenoid valve. 67.Connect the electrical connection to the fuel pressure regulator. 68.Secure the electrical connection for the pressure relief sensor. 69.Connect the electrical connection to the fuel pressure sensor. 70.Refit the electrical wiring in its seat and secure. 71.Tighten the bolts securing the wiring duct to the cylinder head. 72.Connect the electrical connection for the air conditioning compressor engagement solenoid valve. 73.Connect the electrical connection to the timing sensor. 74.Secure the electrical connections to the injectors. 75.Secure the electrical connections to the heater plugs. 76.Connect the electrical connection to the engine oil pressure warning light switch. 77.Connect the electrical connection for the engine rpm sensor. 78.Secure the electrical connection to the engine coolant temperature sensor. 79.Remove the engine from the overhaul stand.