ZEST BOLT Service Manual

Revotron 1.2T 2.7. ENGINE ON VEHICLE SERVICE PROCEDURE A ENGINE REMOVAL. ........................................................................................................................... 87 B ENGINE INSTALLATION. ................................................................................................................... 90 2.8. ENGINE OVEHAULING (ON OVERHAUL STAND) A ENGINE DIS-ASSEMBLY i REMOVAL OF INTAKE MANIFOLD. ............................................................................................. 93 ii REMOVAL OF EXHAUST MANIFOLD. ......................................................................................... 96 iii REMOVAL OF OIL SUMP ........................................................................................................... 100 iv REMOVAL OF SENSORS ........................................................................................................... 100 v REMOVAL OF TIMING BELT ...................................................................................................... 101 vi REMOVAL OF CYLINDER HEAD ............................................................................................... 104 vii REMOVAL OF CYLINDER HEAD SUB-ASSEMBLIES. .............................................................. 105 viii REMOVAL OF CYLINDER BLOCK SUB-ASSEMBLIES ............................................................ 107 B ENGINE ASSEMBLY i FITMENT OF CYLINDER HEAD SUB-ASSEMBLIES. ................................................................ 111 ii FITMENT OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES...................................... 113 iii FITMENT OF CYLINDER BLOCK SUB-ASSEMBLIES .............................................................. 114 iv FITMENT OF CYLINDER HEAD ON CYLINDER BLOCK .......................................................... 117 v FITMENT OF OIL SUMP ............................................................................................................. 123 vi FITMENT OF ENGINE SENSORS AND PERIPHERALS ........................................................... 124 vii FITMENT OF EXHAUST MANIFOLD AND PERIPHERALS. ...................................................... 127 viii FITMENT OF INTAKE MANIFOLD AND PERIPHERALS. .......................................................... 129 2.9. ENGINE MANAGEMENT SYSTEM A ABBREVIATIONS ............................................................................................................................. 135 B AN OVERVIEW. ................................................................................................................................ 136 C ELECTRONIC CONTROL UNIT. ...................................................................................................... 137 D SENSORS i T-MAP SENSOR.......................................................................................................................... 144 ii LAMBDA SENSOR ...................................................................................................................... 146