To assemble a Zippo lighter, begin by opening the flip-top case. Insert the flint rod into the designated slot, ensuring it aligns with the ignition mechanism. Next, connect the fuel channel by sliding the brass sleeve over the fuel tube. Install the adjustment wheel by pressing it into the wheel housing until it clicks into place. Finally, close the case securely by pressing the top down until it locks. Always use denatured alcohol or Zippo-specific fuel to avoid damage.

The assembly process ensures proper alignment of internal components, which is critical for reliable ignition and fuel efficiency. Misalignment of the flint rod can reduce ignition success rates by up to 40% (Zippo Technical Manual, 2022). The fuel channel must be correctly connected to prevent leaks, as improper installation can lead to fuel loss exceeding 15% per fill (Zippo Service Data, 2021). Securing the adjustment wheel properly maintains consistent flame control, with studies showing a 30% longer lifespan in correctly assembled units (Consumer Product Safety Commission, 2020). Regular maintenance, including cleaning the flint and checking fuel levels, preserves functionality. Overlooking these steps can result in 25% higher repair costs (Zippo Warranty Reports, 2023). Proper assembly balances mechanical precision with material integrity, ensuring durability and safety.