ZEST BOLT Service Manual

ENGINE 1.3 QUADRAJET (75PS) 51 3A.1.2.3.4 ENGINE BLOCK – MEASUREMENT, INSPECTION AND GRADE DETERMINATION 1. Clean sealant residues of f the mating surfaces between: cylinder head extension/lower cylinder head, upper crankcase/lower crankcase and lower crankcase/crankcase sump. 2. Clean the parts removed thoroughly and check their condition visually. 3. Fit the water/oil sealing plugs in the crankcase using suitable fitting tools. 4. Lubricate all the mechanical component s with engine oil. 5. Measure the cylinder bore diameter using the diagram illustrated. 6. Check for the values to be wi thin the recommended values for the respective grades as shown below. 1 Cylinder liner diameter - Grade A (mm) 69.600 ~ 69.610 1 Cylinder liner diameter - Grade B (mm) 69.610 ~ 69.620 1 Cylinder liner diameter - Grade C (mm) 69.620 ~ 69.630 7. Check that the taper of the cylinder liners/bores is within the recommended limit s of lesser than 0.010mm Cylinder liner taper (mm) < 0.010 8. Check that the ovality of the cylinder liners is within the recommended limits. Cylinder liner ovality (mm) +/- 0.005 9. If the cylinder bore measurements are not within the recommended limits, ream the cylinder bores following the recommended oversize of 0.1mm. Cylinder liner diameter oversize (mm) 0.1 NOTE : If reaming is undertaken, ensure that all the bores have the same oversize. 10 Use an appropriate support tool to replace the upper crankcase on the overhaul stand. 11 Refit the lower crankcase locating bushes in their seats. 12 Provisionally fit the lower engine block on the upper engine block to measure the main journal seat s and then remove it. 13.Loosen the central M10 bolt s (1a) securing the lower crankcase to a torque of 1.9 ~ 2.1Kg-m +/- 3 0 , following the order shown in the figure. Use the angular tightening tool (1b). 14.Tighten the lower crankcase side M8 bolt s to a torque of 2.9 ~ 3.2 Kg-m, following the order shown in the figure. 15.Check that the diameter of the main journal seats is within specified limit s (without fitting the half- bearings). 3 Main journal seat diameter - Category A (mm) 54.710 ~ 54.714 3 Main journal seat diameter - Category B (mm) 54.714 ~ 54.718 3 Main journal seat diameter - Category C (mm) 54.718 ~ 54.722