Cylinder Block

REMOVAL
1. Remove the cylinder head, timing belt, front case, flywheel, piston and crankshaft.
2. Remove the piston cooling jet (for turbo charger)





Oil Pressure Switch

INSPECTION
Cylinder Block
1. Visually check the cylinder block for scratches, rust and corrosion. Also check for latent cracks or any other defects by using a flaw detecting agent (magna fluxing). Correct or replace the block if defective.





2. Using a straight edge and feeler gauge, check the block top surface for warpage. Make sure that the surface is free from gasket chips and other foreign matter.
Standard 0.05 mm (0.0020 inch) or less
Limit 0.1 mm (0.004 inch)





3. Measure the cylinder bore with a cylinder gauge at three levels in the directions A and B. If the cylinder bores show more than the specified out-of-round or taper or if the cylinder walls are badly scuffed or scored, the cylinder block should be rebored and honed. New oversize pistons and rings must be fitted. Measuring points are as shown.
Cylinder I.D 75.5 mm (2.972 inch)
Cylinder I.D taper 0.02 mm (0.0008 in. or less)
4. If a cylinder ridge exists, cut away with a ridge reamer.
5. Oversize pistons are available in four sizes.
Piston service size and mark mm (inch)
0.25 (0.010) O.S 25
0.50 (0.020) O.S 50
0.75 (0.030) O.S 75
1.00 (0.039) O.S 100
6. When boring the cylinder bore to oversize, keep the specified clearance between the oversize piston and the bore, and make sure that all pistons used are of the same oversize.
The standard measurement of the piston outside diameter is taken at a level 12 mm (0.47 inch) above the bottom of the piston skirt and across the thrust faces.
Piston-to-cylinder wall clearance 0.02 - 0.04 mm (0.0008 - 0.0016 inch)





OIL PRESSURE SWITCH
1. If "OIL PRESSURE" indicating lamp lights when ignition switch is set to "ON" and goes out when engine is started and runs at idle, then everything is in order. If "OIL PRESSURE" lamp does not light when ignition switch is set to "ON", check switch, lamp and wiring.
2. If there is current flow when ignition switch is set to "ON" and if there is no current flow when engine is running at idle, switch is good.
If switch is good, check lamp wiring.
Oil pressure switch operation pressure 14.71 - 29.42 kPa (0.15 - 0.3 kg/cm2, 2.1 - 4.3 psi)





3. Using the special tool (09260-32000), tighten the switch to the specified torque.

NOTE: Do not over torque the oil pressure switch.

Tightening torque
Oil pressure switch and sender assy 8 - 12 Nm (80 - 120 kg.cm, 6 - 9 ft. lbs.)
Oil pressure switch adaptor 13 - 15 Nm (130 - 150 kg.cm, 10 - 11 ft. lbs.)

INSPECTION





1. Check the continuity between the terminal and the body with an ohmmeter.
If there is noncontinuity, replace the oil pressure switch.





2. Check the continuity between the terminal and the body when the fine wedge is pushed. If there is continuity even when the fine wedge is pushed, replace it.
3. Or, if there is no continuity when a 50 kPa (70 psi) vacuum is applied through the oil hole, the switch is operating properly.
Check to see that air doesn't leak. If air leaks, the diaphragm is broken. Replace the switch.