ZEST BOLT Service Manual

ENGINE 1.3L QUADRAJET (90PS) 49 46.Apply a strip of grey silicone sealant to the contact surfaces between the crankcase sump and lower engine block as shown in the diagram in the figure. NOTE : The sealant strip must be continuous and unbroken. The sealant strip diameter must be 3.0 - 4.0 mm. 48.Place the bracket (2a) in its housing and secure it by tightening the M8 bolts (2b) to a torque of 2.7 ~ 3.3 Kg-m. 49.Rotate the engine through 180° on the overhaul stand. 50.Place the engine oil dipstick pipe back in its housing and fasten it with the bolt. 51.Close the oil vapour pipe retaining clip. 52.Place the intermediate driveshaft mount in position and secure it tightening the M8 bolts to a torque of 2.0 ~ 2.4 Kg-m. 53.Remove the tool 287158900651 (Hose). 54.Position the crankcase pulley support flange in its housing & secure it with the left threaded bolt without tightening it to the recommended torque. 55.Place the water pump, complete with gasket in position, and then tighten the M10 bolts to a 0.8 ~ 1.0 Kg-m torque. 56.Position the crankshaft pulley in its housing and secure it without tightening the bolts 57.Position the engine components single belt moving tensioner in its housing and secure it tightening the M10 bolt to a torque of 4.5 ~ 5.5 Kg-m . 58.Position the engine components single belt moving tensioner in its housing and secure it tightening the M10 bolt to torque of 4.5 ~ 5.5 kg-m. 59.Position the auxiliary drive belt fixed tensioner in its housing and secure it tightening the M8 bolt to a torque of 2.2 ~ 2.7 Kg-m . 60.Adjust the mobile tensioner with a wrench and fit the auxiliary drive belt. 61.Place the timing side rigid engine support in its housing with the engine lift bracket and secure it tightening the M10 bolts to a torque of 5.7 ~ 6.3 kg-m. 62.Place the turbocharger unit complete with catalytic converter back in its housing and secure it by tightening the M8 nuts to a torque of 2.2 ~ 2.7 Kg- m . 63.Refit the exhaust manifold heat shield with the engine lift bracket and secure with the nut and bolts. 64.Position the pipe carrying engine oil to the turbocharger in its housing and secure it tightening M10 connectors to a torque of 1.3 ~ 1.6 Kg-m. 47.Position the crankcase sump (1a) in its housing and secure it tightening theM6 bolts (1b) to a torque of 0.8 ~ 1.0 Kg-m and the M6 nuts (1c) to a torque of 0.8 ~ 1.0 Kg-m. NOTE : Follow the order shown in the figure for each tightening sequence. The tightening to 0.8 - 1.0 Kg-m is performed in two stages: pre tightening to 0.4 Kg-m followed by an additional tightening of 0.8 - 1.0 Kg-m.