ZEST BOLT Service Manual

ENGINE 1.3L QUADRAJET (90PS) 61 32.After checking all the main journals, apply a strip of specified silicon sealant to the contact surfaces between the lower crankcase and the upper crankcase as shown in the figure above. NOTE : The sealant strip must be unbroken. The sealant strip diameter must be 2.5 - 3.5 mm. 33.After applying the sealant clean the crankshaft lower oil seal seat. 34.Fit the lower crankcase to the upper crankcase permanently by tightening the bolts as shown previously. 35.Check that the small end bush bore (inner diameter) diameter is within the recommended limits of 23.006 mm ~ 23.012 mm; if not, replace the connecting rod assemblies. 36.Check that the diameter of the gudgeon pin housing in the piston is within the recommended values of 22.990 mm ~ 22.996 mm. 37.If the piston pin bore diameter is not within specified values, replace the piston complete with its piston pin and rings. 38.Check that the outer diameter of the piston pins is within the recommended limits of 22.982 mm ~ 22.987 mm; if not, replace the worn piston pins. 39.Fit the piston rings in the cylinder bore and check that the opening between the ends is within the recommended values; if this is not the case, replace the retaining rings. 40.Check that the thickness of the piston rings is within the recommended limits. 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) 1.54 ~ 1.56 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. Cylinder compression 1st sealing 1.970 ~ 1.995 ring thickness (mm) Cylinder compression 2nd sealing 1.470 ~ 1.490 ring thickness (mm) Piston oil scraper ring size (mm) 1.970 ~ 1.990 Cylinder compression 1st sealing 0.20 ~ 0.30 ring gap (mm) Cylinder compression 2nd sealing 1.0 ~ 1.5 ring gap (mm) Piston oil scraper ring gap (mm) 0.25 ~ 0.50