Isuzu N-Series. Service manual — part 510
Engine Mechanical (4HK1-TC) 6A-145
5-8840-0266-0 (J-45059)
Angle Gauge
Illustration
Tool Number /
Description / Remarks
6A-146 Engine Mechanical (4HK1-TC)
Cylinder Block
Component
Legend
1. Cylinder Liner
2. Cylinder Block
3. Cover (For Europe)
Removal
1. Demount the engine assembly.
Refer to “Engine Assembly”.
2. Remove the cylinder head cover.
Refer to “Cylinder Head Cover”.
3. Remove the rocker arm shaft assembly.
Refer to “Rocker Arm Shaft Assembly”.
4. Remove the camshaft assembly.
Refer to “Camshaft Assembly”.
5. Remove the cylinder head.
Refer to “Cylinder Head”.
6. Remove the fuel supply pump.
Refer to “Fuel Supply Pump” in Section 6C.
7. Remove the crankshaft front oil seal.
Refer to “Crankshaft Front Oil Seal”.
8. Remove the crankshaft rear oil seal.
Refer to “Crankshaft Rear Oil Seal”.
9. Remove the oil pan.
Refer to “Oil Pan”.
10. Remove the water pump.
Refer to “Water Pump” in Section 6B.
11. Remove the front cover.
Refer to the “Front Cover”.
N6A6281E
Engine Mechanical (4HK1-TC) 6A-147
12. Remove the timing gear train.
Refer to “Timing Gear Train”.
13. Remove the oil pump.
Refer to “Oil Pump”.
14. Remove pistons and connecting rods.
Refer to “Pistons and Connecting Rod”.
15. Remove the crankshaft.
Refer to “Crankshaft”.
16. Remove piston oil jet.
17. Remove the cylinder liner.
If the cylinder liner cannot be pulled free by hand,
tap around the lower side of the liner with a
hammer grip or similar object loosen it.
Inspection
1. Carefully remove water stains or other foreign
matters on the surface of the cylinder block.
• Be careful not to damage the cylinder block.
2. Carefully remove the liquid gasket on the
crankcase mounting surface.
3. Clean up the cylinder block.
4. Visually inspect the cylinder block.
• Conduct color check and hydraulic (or
pneumatic) test and if you find crack or other
damage, replace the cylinder block.
5. Cylinder liner wear measurement
• Check the internal surface of the liner for flaw or
damage.
• Measure the liner bore diameter at the most
worn part (it wears more in the rotation
direction) at 15 – 20 mm (0.59 – 0.79 in) from
the top end of the liner with the liner installed in
the cylinder block. If the wear is over the
application limit, replace it.
N6A6282E
Cylinder liner bore diameter
mm (in)
Standard
115.021 – 115.050
(4.52837 – 4.52952)
Limit
115.20 (4.5354)
N6A6283E
N6A6284E
6A-148 Engine Mechanical (4HK1-TC)
Caution:
You need not select piston grade since cylinder liner
bore is only available in one size against the liner grade
selection of its outer diameter.
6. Cylinder block upper face warpage
• Pull out the cylinder liners and remove water
stains on the cylinder block.
• Measure four sides and two diagonals of the
top surface of the cylinder block using a straight
edge and a thickness gauge.
• Replace the cylinder block if the measurements
exceed limit values.
Installation
1. Cylinder liner grade selection
• Select liner outer diameter grades according to
the cylinder block bore grades stamped on the
cylinder block at arrowed positions in the figure.
(Reference)
When replacing liners, a “liner set” let you
obtain a piston of proper grade for a given liner
bore diameter only by specifying a liner outside
diameter grade.
2. Install the cylinder liners.
• Install the cylinder liners perpendicular to the
cylinder block.
• Do not hammer the liner or apply excessive
force to insert it.
Caution:
Clean up and blow with compressed air the cylinder
block and the cylinder liners before installing them.
Cylinder block upper face warpage
mm (in)
Standard
0.05 or less (0.002 or less)
Limit
0.20 (0.079)
Grade matching of cylinder block and liner
Grade of Cylinder block (stamp)
1, 2
3
Grade of Liner outside diameter
1X
3X
N6A6285E
Cylinder block bore and liner grade
(for reference)
mm (in)
Grade
(1,2)/(1X)
(3)/(3X)
Cylinder
block
Bore
diameter
118.001 – 118.020
(4.64699 –
4.64654)
118.021 – 118.030
(4.64649 –
4.64684)
Liner
outside
diameter
117.991 – 118.000
(4.64531 –
4.64566)
118.001 – 118.010
(4.64570 –
4.64605)
N6A6286E
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