ZEST BOLT Service Manual

ENGINE 1.3 QUADRAJET (75PS) 52 27.Fit the calibrated wire (1) (plastic gage) for measuring the bearing clearance. 16.Check that there are no deposits or blockages in the crankshaft lubrication ducts. 17 Check that the diameter of the main journals corresponds to the recommended figures. Main journal diameter - Category A (mm) 50.994 ~ 51.000 Main journal diameter - Category B (mm) 50.988 ~ 50.994 Main journal diameter - Category C (mm) 50.982 ~ 50.988 18.If the diameter of the main journals is not within the specified limits, they should be reground to the recommended undersize of 0.127mm. Main journal diameter undersize (mm) 0.127 NOTE : The crankpin undersize should not be higher than the specified values as it will adversely affect the structural resistance of the crankshaft (following contact between the tool and rolled connectors). As far as the above is concerned, if the regrinding requires an undersize greater than 0.127 mm, then the crankshaft must be replaced with a new one. For an undersize of more than 0.127mm, only the half bearings should never be replaced, even if it is available for purchase. 19 Check that the diameter of the crankpins corresponds to the recommended figures. Crankpin diameter - Category A (mm) 42.591 ~ 42.600 Crankpin diameter - Category B (mm) 42.582 ~ 42.591 20. If the diameter of the crankpins is not correct, they should be reground to the recommended undersize of 0.127 mm. Crankpin diameter undersize (mm) 0.127 21.Check the crankshaft and connecting rod bearings, having in mind that no adjustment operations should be carried out on the half-bearings. Replace them if scoring or signs of binding are noted. 22.The size of the main journal half-bearings is given. Main journal half-bearings - Category A (red) (mm) 1.836 ~ 1.841 Main journal half-bearings - Category B (blue) (mm) 1.841 ~ 1.846 Main journal half-bearings - Category C (yellow) (mm) 1.846 ~ 1.851 Main journal half-bearings thickness oversize (mm) 0.127 23.The size of the connecting rod half-bearings is given. Crankpin half-bearings - Category A (red) (mm) 1.546 ~ 1.552 Crankpin half-bearings - Category B (blue) (mm) 1.550 ~ 1.556 Connecting rod half-bearing thickness oversize (mm) 0.127 24.Place the upper main bearing halves in their seats taking great care over cleanliness. NOTE : Half-bearings of different categories may be fitted to the same journal to reduce the clearance. In the above case, observe the following installation requirements: Fit the thickest half-bearing to the main bearing cap and the thinnest to the crankcase. If the crankshaft has been ground, fit new oversize half-bearings to restore the initial tolerance conditions. The thrust half-rings are built into the central main bearing half. 25.The thrust half-ring thickness should be within the specified limits of 2.310 mm ~ 2.360 mm. NOTE : The thrust half-washer undersize is 0.127 mm. 26 Fit the crankshaf t into it s seat on the upper crankcase.