ZEST BOLT Service Manual

ENGINE 1.3L QUADRAJET (90 PS) 1 CONTENTS SR. NO. DESCRIPTION PAGE NO. 3A.1.1. GENERAL INFORMATION 4 3A.1.1.1 TECHNICAL SPECIFICATIONS 4 3A.1.1.2 TIGHTENING TORQUES 5 3A.1.1.3 SPECIAL TOOLS 7 3A.1.1.4 MAINTENANCE, INSPECTION AND TESTS 12 A. ENGINE OIL REPLACEMENT 12 B. ENGINE OIL FILTER CARTRIDGE REPLACEMENT. 13 C. AIR FILTER INSPECTION AND CLEANING 14 D. AIR FILTER ASSEMBLY - REMOVAL 16 E. FUEL FILTER REPLACE 17 F. ON VEHICLE TIMING CHAIN REPLACEMENT PROCEDURE 18 3A.1.2 ENGINE – MECHANICAL 22 3A.1.2.1 REMOVAL OF ENGINE FROM VEHICLE 22 3A.1.2.2 CYLINDER HEAD ASSEMBLY 26 3A.1.2.2.1 EXPLODED VIEW 26 3A.1.2.2.2 REMOVAL OF CYLINDER HEAD ASSEMBLY AND OIL SUMP 26 3A.1.2.2.3 CYLINDER HEAD – OVERHAUL 35 3A.1.2.2.4 VALVE AND VALVE SPRING 38 A. EXPLODED VIEW 38 B. REMOVALAND OVERHAUL 38 C. INSTALLATION 40 3A.1.2.2.5 CYLINDER HEAD BLOCK 41 A. HEAD GASKET CORRECTION BASED ON CYLINDER HEAD BLOCK PLANARITY. 41 B. CAMSHAFT HOUSING INSPECTION AND MEASUREMENT. 42 C. CYLIDER HEAD BLOCK ASSEMBLY – REFITTING. 43 3A.1.2.2.6 SELECTION OF CYLINDER HEAD GASKET 44 3A.1.2.2.7 INSTALLATION OF CYLINDER HEAD ASSEMBLY AND OIL SUMP 45 3A.1.2.3 ENGINE BLOCK 51 3A.1.2.3.1 DISMANTLING 51 3A.1.2.3.2 PISTON - REMOVALAND FITMENT. 55 3A.1.2.3.3 ENGINE OIL PUMP - REMOVALAND FITMENT. 56 3A.1.2.3.4 ENGINE BLOCK – MEASUREMENT, INSPECTION AND GRADE DETERMINATION 58 3A.1.2.3.5 ENGINE BLOCK – ASSEMBLING 64