ZEST BOLT Service Manual

ENGINE 1.3L QUADRAJET (90PS) 58 15.Check that the diameter of the main journal seats is within specified limits (without fitting the half- bearings). 3A.1.2.3.4 ENGINE BLOCK - MEASUREMENT, INSPECTION & GRADE DETERMINATION 1. Clean sealant residues off the mating surfaces between: cylinder head extension/lower cylinder head, upper crankcase/lower crankcase and lower crankcase/crankcase sump. 2. Clean the parts removed thoroughly and check their condition visually. 3. Fit the water/oil sealing plugs in the crankcase using suitable fitting tools. 4. Lubricate all the mechanical components with engine oil. 5. Measure the cylinder bore diameter using the diagram illustrated. 6. Check for the values to be within the recommended values for the respective grades as shown below. 1 Cylinder liner diameter - 69.600 ~ 69.610 GradeA (mm) 1 Cylinder liner diameter - 69.610 ~ 69.620 Grade B (mm) 1 Cylinder liner diameter - 69.620 ~ 69.630 Grade C (mm) 7. Check that the taper of the cylinder liners/bores is within the recommended limits of lesser than 0.010mm Cylinder liner taper (mm) < 0.010 8. Check that the ovality of the cylinder liners is within the recommended limits. Cylinder liner ovality (mm) +/- 0.005 9. If the cylinder bore measurements are not within the recommended limits, ream the cylinder bores following the recommended oversize of 0.1mm. Cylinder liner diameter oversize (mm) 0.1 NOTE : If reaming is undertaken, ensure that all the bores have the same oversize. 10 Use an appropriate support tool to replace the upper crankcase on the overhaul stand. 11 Refit the lower crankcase locating bushes in their seats. 12 Provisionally fit the lower engine block on the upper engine block to measure the main journal seats and then remove it. 13.Loosen the central M10 bolts (1a) securing the lower crankcase to a torque of 1.9 ~ 2.1Kg-m +/- 3 0 , following the order shown in the figure. Use the angular tightening tool (1b). 14.Tighten the lower crankcase side M8 bolts to a torque of 2.9 ~ 3.2 Kg-m, following the order shown in the figure.