ZEST BOLT Service Manual

ENGINE 1.3 QUADRAJET (75PS) 54 46.Fit the caps (1b) on the connecting rods (1a) and secure them by tightening the M8 bolst (1c) to the recommended torque of 1.9 ~ 2.1daN m + 40° +/ - 2°. NOTE : The connecting rods are pre-set fracture type and are supplied already fractured by Parts together with the cap bolts. The connecting rod caps are not interchangeable because the fracture profile differs from part to part. 47.Check that the big end diameter (2) (without fitting the half-bearings) is within the recommended limist of 45.734 mm ~ 45.744mm; if not, replace the connecting rods. 48.Check that there are no signs of seizing on the flywheel ring gear teeth; if this is not the case, replace it. 49.Refit the engine oil jets in their seats and secure by tightening the M6 bolts to a torque of 0.8 ~ 1.0 Kg-m . NOTE : The crankshaft supplied by the Parts Dept. 40.Check that the thickness of the piston rings is within the recommended limits. Cylinder compression 1st sealing ring thickness (mm) 1.970 ~ 1.995 Cylinder compression 2nd sealing ring thickness (mm) 1.470 ~ 1.490 Piston oil scraper ring size (mm) 1.970 ~ 1.990 41.Check that the piston ring seats are within the following recommended values. Sealing ring seat in piston - 1st groove (mm) 2.08 ~ 2.10 Sealing ring seat in piston - 2nd groove (mm) 1.53 ~ 1.55 Sealing ring seat in piston - 3rd groove (mm) 2.02 ~ 2.04 42 Check that the outer diameter of the pistons corresponds to the recommended figures; if not, replace the piston complete with piston rings and gudgeon pin. Piston outer diameter - Grade A (mm) 69.520 ~ 69.530 Piston outer diameter - Grade B (mm) 69.530 ~ 69.540 Piston outer diameter - Grade C (mm) 69.540 ~ 69.550 NOTE : Measure perpendicular to the gudgeon pin axis, 12 mm from the lower edge of the skirt. 43.Check that the axial clearance between the first ring and the housing in the piston corresponds to the recommended figures of 0.09 mm ~ 0.13mm. 44.Check that the backlash (1a) between the second ring (1b) and the housing in the piston (1c) corresponds to the recommended figure of 0.04 mm ~ 0.08 mm. 45 Check that the backlash between the oil scraper ring and the housing in the piston corresponds to the recommended f igures of 0.030mm ~ 0.070mm. comes without half-bearings and the main journals and crankpins are the “normal” size; the half- bearings to be fitted must therefore be selected identifying the class of each main journal and crankpin for the new crankshaft.