Isuzu KB P190. Manual — part 219

ENGINE MECHANICAL 6A – 71

Cylinder Liner Grade Selection

Subtract the average cylinder body bore from the average
cylinder liner outside diameter to obtain the fitting interference.

Fitting Interference

mm

(in)

Standard

-0.0010*-0.019 (-0.00004*-0.0007)

* A minus (-) value indicates that the cylinder body bore is
smaller than the liner outside diameter.

Cylinder Body Bore Measurement

1. Take measurements at measuring point (1) across

positions 1-1 and 2-2.

Measuring Point (1):

4JA1T(L), 4JA1TC : 13,48,83,118,153 mm
(0.51,1.89,3.27,4.65,6.02 in)

4JH1TC : 18,53,88,123,158 mm (0.71,2.09,3.46,4.84,6.22
in)

Cylinder Liner Grade Selection and Standard
Fitting Interference

Accurately measured fitting interference and proper cylinder
liner grade selection are extremely important.

If the cylinder liner fitting interference is too small, engine
cooling efficiency will be adversely affected.

If the cylinder liner fitting interference is too large, it will be
difficult to insert the cylinder liner into the cylinder body.

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6A – 72 ENGINE MECHANICAL

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A mark was stamped on the upper side of the cylinder block
during production to indicate the correct liner.

The liner grade (i.e.1.2.3.4) is indicated in metal stamp.

Cylinder Liner Grade

4JA1T (L), 4JA1TC

mm (in)

Liner

Outside

Grade

Cylinder Body

Bore Diameter

Liner Outside

Diameter

Liner Bore

Grade

Service Liner Bore Measurement

AX 93.035-93.050

(3.6628-3.6634)

1

95.001-95.010

(3.7402-3.7405)

95.011-95.020

(3.7406-3.7409)

CX 93.051-93.066

(3.6634-3.6640)

AX 93.035-93.050

(3.6628-3.6634)

2

95.011-95.020

(3.7406-3.7409)

95.021-95.030

(3.7410-3.7413)

CX 93.051-93.066

(3.6634-3.6640)

AX 95.035-93.050

(3.6628-3.6634)

3

95.021-95.030

(3.7410-3.7413)

95.031-95.040

(3.7414-3.7417)

CX 93.051-93.066

(3.6634-3.6640)

AX 93.035-93.050

(3.6628-3.6634)

4

95.031-95.040

(3.7414-3.7417)

95.041-95.050

(3.7418-3.7421)

CX 93.051-93.066

(3.6634-3.6640)

4JH1TC

mm (in)

Liner

Outside

Grade

Cylinder Body

Bore Diameter

Liner Outside

Diameter

Liner Bore

Grade

Service Liner Bore Measurement

AX

95.435-95.450 (3.7573-3.7579)

1

97.001-97.010

(3.8189-3.8193)

97.011-97.020

(3.8193-3.8197)

CX

95.451-95.466 (3.7579-3.7585)

AX

95.435-95.450 (3.7573-3.7579)

2

97.011-97.020

(3.8193-3.8197)

97.021-97.030

(3.8197-3.8200)

CX

95.451-95.466 (3.7579-3.7585)

AX

95.435-95.450 (3.7573-3.7579)

3

97.021-97.030

(3.8197-3.8200)

97.031-97.040

(3.8200-3.8205)

CX

95.451-95.466 (3.7579-3.7585)

AX

95.435-95.450 (3.7573-3.7579)

4

97.031-97.040

(3.8200-3.8205)

97.041-97.050

(3.8205-3.8209)

CX

95.451-95.466 (3.7579-3.7585)

ENGINE MECHANICAL 6A – 73

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 liner and

bore surfaces.

NOTE:

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.

Cylinder Liner Installer : 5-8840-2040-0 (4JA1L/TC)

: 5-8840-2313-0 (4JH1TC)

5. (3) is directly beneath the bench press shaft center (4).

NOTE:

Check that the cylinder liner is set perpendicular to
the bench press and that there is no wobble.

6. Use the bench press to apply a seating force of 4,900

N (500 kg/1,100 Ib) to the cylinder liner.

7. Apply a force of 24,500 N (2,500 kg/5,500 Ib) to fully

seat the cylinder liner.

8. After installing the cylinder liner, measure the cylinder

liner projection.

Refer to "Cylinder Liner Projection Inspection".

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6A – 74 ENGINE MECHANICAL

Piston Grade Selection

Measure the cylinder liner bore after installing the cylinder liner.
Then select the appropriate piston grade for the installed
cylinder liner.

1. Measure the cylinder liner bore.

Refer to "Cylinder Liner Bore Measurement"

Cylinder Liner Bore (Service Part) Grade

mm (in)

Grade

Bore

measurement

AX

93.035-95.050

(3.6628-3.6634)

4JA1T(L)

4JA1TC

CX

93.051-95.066

(3.6634-3.6640)

AX

95.435-95.450

(3.7573-3.7579)

4JH1TC

CX

95.451-95.466

(3.7579-3.7585)

NOTE:

It is most important that the correct piston grade be
used. Failure to select the correct piston grade will
result in engine failure. Always measure the cylinder
bore and select the correct piston grade.