ZESTBOLT SERVICE MANUAL

Revotron 1.2T 8 Fastener Fastener Type and Size Torque (Kgfm) (Nm) Tube Assembly (TC Oil Inlet) on TC and Cylinder Block Pipe Union Bolt M10 X 1 2 20 Tube Assembly (TC Oil Inlet) on Thermostat Cover HEX.FL.Nut AM6 1 9.81 Tube Assembly (TC Oil Return) on TC and Cylinder Block HEX.FL.Screw M6 1 9.81 Piston Cooling Nozzle on Cylinder Block Cap Screw M5 0.8 8 Water Pump to Cylinder Block Assembly HEX.Screw M6 1 9.81 Thermostat Cover to Cylinder Head HEX.FL.Nut AM6 1 9.81 Water Inlet Elbow to Cylinder Block HEX.FL.Screw M8 2 20 Adaptor Assembly for Hose Cabin Heater in on Cylinder Head. HEX.FL.Screw M6 1 9.81 Pipe Assembly (TC to IC - 1 of 2) to TC HEX.FL.Nut AM6 1 9.81 Support Bracket (TC to IC Pipe) to FEM HEX.FL.Screw M6 1 9.81 Pipe Assembly (TC to IC - 3 of 4) to FEM HEX.FL.Screw M6 1 9.81 Pipe Assembly (IC to IM - 1) to FEM HEX.FL.Screw M6 1 9.81 Pipe Assembly (IC to IM - 3) to Support Bracket HEX.FL.Screw M6 1 9.81 Bracket Air Filter Mounting to Intake Manifold HEX.FL.Screw M6 1 9.81 Snorkel Mounting Bracket on FEM HEX.FL.Screw M8 2 20 Air Filter on Cylinder Head Cover HEX.FL.Screw M6 1 9.81 Lifting Hooks to Cylinder Head HEX.FL.Bolt M8 2.5 25 Engine Mounting Arm Bracket to Cylinder Head HEX.FL.Nut AM10 4.5 44 A/C Compressor Bracket to Cylinder Block HEX.FL.Bolt/Screw M8 2.5 25 A/C Compressor to A/C Compressor bracket HEX.FL.Bolt M8 2.5 25 Note : 1. Sequence for Cylinder Head bolt tightening during engine assembly : A. Step 1 : Tighten to 3 kgm in the sequence as marked. Step 2 : Tighten to 5 kgm in the same sequence as marked. Step 3 : Tighten to 6.5 kgm in the same sequence as marked. B. Alternatively all screws to be machine tightened simultaneously as per each step shown above. (Bolt tightening sequence is marked in "On vehicle engine assembly" procedure. 2. Oil Filter fitment procedure : Apply oil on seal face and screw in until seal touches face. Tighten further by 3/4 turn. Do not over tighten.

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