Isuzu N-Series. Service manual — part 576
GENERAL ENGINE MECHANICAL 6A-61
Cylinder Liner Installation
1. Cylinder Liner Installation Using The Special Tool.
1) Use new kerosene or diesel oil to thoroughly
clean the cylinder liners and bores.
2) Use compressed air to blow-dry the cylinder lin-
er and bore surfaces.
Cylinder Liner Installer
: 5-8840-2313-0 (4JG2 / 4JH1-TC)
: 5-8840-2040-0 (4JB1 / 4JB1-TC)
Notice:
All foreign material must be carefully removed from the
cylinder liner and the cylinder bore before installation.
3) Insert the cylinder liner (1) into the cylinder
body (2) from the top of the cylinder body.
4) Set the cylinder liner installer (3) to the top of
the cylinder liner.
Position the cylinder body so that the installer
center is directly beneath the bench press shaft
center (4).
Cylinder Liner Installer
: 5-8840-2313-0 (4JG2 / 4JH1-TC)
: 5-8840-2040-0 (4JB1 / 4JB1-TC)
Notice:
Check that the cylinder liner is set perpendicular to the
bench press and that there is no wobble.
5) Use the bench press to apply a seating force of
500 kg (1,102.5 lb/4,900 N) to the cylinder liner.
6) Apply a force 2,500 kg (5,512.5 lb/24,500 N) to
fully seat the cylinder liner.
7) After installing the cylinder liner, measure the
cylinder liner projection.
8) After installing the cylinder liner, measure the
cylinder liner projection.
Refer to “Cylinder Liner Projection Inspection”
in this Section.
Measure the cylinder liner bore inside diameter
and select the appropriate piston grade.
Reassembly
1. Cylinder Block
2. Tappet
3. Camshaft
• Apply a coat of engine oil to the tappet and the
cylinder body tappet insert holes.
• Locate the position mark applied at disassem-
bly (if the tappet is to be reused).
• Apply a coat of engine oil to the camshaft and
the camshaft bearings.
• Install the camshaft to the cylinder body.
Take care not to damage the camshaft bear-
ings.
N6A3201E
N6A3202E
6A-62 GENERAL ENGINE MECHANICAL
4. Crankshaft
5. Main Bearing Cap
6. Crankshaft Rear Oil Seal
7. Cylinder Block Rear Plate
8. Flywheel
Above works refer to “CRANKSHAFT” Section in
this manual.
9. Piston and Connecting Rod
1) Try to insert the piston pin into the piston pin
hole with normal finger pressure.
Weigh each piston and connecting rod assem-
bly.
Select piston and connecting rod combinations
so that the weight variation of the different as-
semblies is held within the specified limits.
2) Clamp the connecting rod in a vise.
Take care not to damage the connecting rod.
3) Use a pair of pliers to install the piston pin snap
ring to the piston.
Notice:
When changing piston/connecting rod combinations, do
not change the piston/piston pin combination.
4) Install the piston to the connecting rod.
The piston head front mark (1) and the connect-
ing rod “ISUZU” casting mark (2) must be fac-
ing the same direction.
5) 5Apply a coat of engine oil to the piston pin and
the piston pin hole.
Use your fingers to force the piston pin into the
piston until it makes contact with the snap ring.
g (oz)
Variance in weight after
assembly
Less than 3 (0.1058)
N6A3106E
N6A3173E
N6A3205E
GENERAL ENGINE MECHANICAL 6A-63
6) Use your fingers to force the piston pin snap
ring into the piston snap ring groove.
Check that the connecting rod moves smoothly
on the piston pin.
7) Install the piston rings with the piston ring ex-
pander.
The compression ring must be set with the 1N,
2N mark (4JG2) facing up.
Discrimination mark is painted as shown in the
illustration.
8) Use a piston ring replacer to install the three
piston rings.
Piston Ring Replacer:
Install the piston rings in the numerical order
shown in the illustration.
4JB1, 4JH1-TC
N6A3206E
N6A3207E
Legend
1. N mark (Top ring) (2nd ring) (4JB1)
2. 1N mark (Top ring) 2N mark (2nd ring) (4JG2)
3. R mark (Top ring) (2nd ring) (4JH-TC)
Legend
1. Oil ring
2. 2nd compression ring
3. 1st compression ring
N6A3178E
N6A3188E
6A-64 GENERAL ENGINE MECHANICAL
4JG2
Notice:
Install the compression rings with the stamped side fac-
ing up.
Insert the expander coil into the oil ring groove so that
there is no gap on either side of the expander coil before
installing the oil ring.
9) Apply engine oil to the piston ring surfaces.
10) Check that the piston rings rotate smoothly in
the piston ring grooves.
11) Position the piston ring gaps as shown in the il-
lustration.
12) Carefully wipe any oil or other foreign material
from connect rod bearing back face and the
connecting rod bearing fitting surface.
13) Apply a coat of engine oil to the upper bearing
surfaces.
Apply a coat of engine oil to the cylinder wall.
14) Position the piston head from mark so that it is
facing the front of engine.
Use the piston ring compressor to compress
the piston rings.
Piston Ring Compressor: 5-8840-9018-0 (J-
8037)
15) Use a hammer grip to push the piston in until
the connecting rod makes contact with the
crankpin.
At the same time, rotate the crankshaft until the
crankpin is at BDC.
Legend
1. Oil ring
2. Compression ring No. 2
3. Compression ring No. 1
N6A3189E
N6A3208E
Legend
1. No. 1 Compression ring
2. No. 2 Compression ring
3. Oil ring
4. Expand ring
5. Front mark
N6A3314E
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