ZEST BOLT Service Manual

ENGINE 1.3 QUADRAJET (75PS) 82 G. FUEL FILLER CAP: The fuel tank filler neck has a vented Fuel cap. Inside the fuel filler cap is a pressure release valve.This allows it to vent the fumes in and out from fuelatnk if they build up to predetermined levels.The fuel filler cap has O’ring around the neck. This O’ ring should be inspected for cracks or inflexibility . If the O’ ring become cracked or inflexible, it should be replaced to keep the environment clean.A ratchet tightening device on the threaded fuel filler cap reduces the chances of over tightening and incorrect insat llation. After the ‘O’ ring on fuel filler cap and the fuel filler neck flange contacts, the ratchet produces a loud clicking sound, indicating the seal has been set. REMOVAL / INSPECTION: 1. Remove fuel filler cap. 2. Check O ring for even filler neck imprint. 3. Check O ring for any deterioration or any dam- age. If found damaged replace fuel filler cap. 4. Check vent mechanism by simply applying mouth air pressure at threaded cap. For any deteriora- tion or any damage in vent mechanism replace fuel filler cap. NOTE : IN CASE OF FUEL FILLER CAP, REPLACEMENT TO BE DONE WITH CORRECT CAP. OTHERWISE IT MAY RESULT IN CRITICAL MALFUNCTION OF THE SYSTEM. H. FUEL HOSES & LINES: The delivery and return lines are made of nylon pipes with quick fix couplings at joints. REMOVAL: 1. Disconnect the quick fix couplings by pressing the two tabs from the lines. INSPECTION: 1. Visually check all hoses and pipes connected via clamp and quick connectors for leaks, loose con- nections, deterioration or damage, hose crack etc. Replace if necessary. 2. Make sure that all clamp s and quick connectors are secure. 3. If the pipe clamps found deformed, bent or bro- ken, replace with new one. FILLER ASSEMBLY: 1. Do not tighten the clamps used on filler hose ex- cessively to avoid damage to hoses. 2. Fuel hoses to filler pipe vary for each type of pipe. Necessary care to be taken to connect and clamp each hose correctly. 3. Do not kink or twist hose / pipe when they are routed. 4. Connect negative terminal at battery. 5. Turn ignition switch ON and run engine idle. Check for fuel leakages. CAP RETAINER TAG SEAL THREADED CAP SNAP MECHANISM FOR FILLER DOME REMOVE SLOWLY FUEL SPARY MAY CAUSE INJURY TOP VIEW DIESEL