Isuzu engine 4j series. Manual — part 30
6A – 56
GENERAL ENGINE MECHANICAL
CYLINDER BLOCK
DISASSEMBLY
1. Cylinder Head Assembly and Gasket
2. Oil Pan Assembly
3. Timing Gear
3a. Timing Belt and Pulley
4. Front Oil Seal (Belt Drive Model)
5. Timing Gear Housing
5a. Timing Pulley Housing
6. Oil Pump Assembly
6A-56-1.tif
Disassembly steps
1. Cylinder head Assembly and
gasket
2. Oil pan Assembly
3. Timing gear
3a. Timing belt and pulley
4. Front oil seal
5. Timing gear housing
5a. Timing pulley housing
6. Oil pump Assembly
7. Piston cooling oil pipe
8. Piston and connecting rod
9. Flywheel
10. Cylinder block rear plate
11. Crankshaft rear oil seal
12. Main bearing cap
13. Crankshaft
14. Camshaft
15. Tappet
16. Cylinder block
Reassembly steps
To reassemble, follow the
disassembly steps in the reverse
order.
5a
GENERAL ENGINE MECHANICAL 6A – 57
7. Piston Cooling Oil Pipe
8. Piston and Connecting Rod
9. Flywheel
10. Cylinder Block Rear Plate
11. Crankshaft Rear Oil Seal
12. Main Bearing Cap
13. Crankshaft
14. Camshaft
15. Tappet
16. Cylinder Block
INSPECTION AND REPAIR
Make the necessary adjustments, repairs, and part
replacements if excessive wear or damage is discovered
during inspection.
1. Remove the gasket and any other material adhering
the upper surface of the cylinder block.
Be very careful not to allow any material to accidental
drop into the cylinder block.
Be very careful not to scratch the cylinder block.
2. Carefully remove the oil pump, Rear Seal retainer and
oil pan installation surface seal.
3. Wipe the cylinder block clean.
Cylinder Liner Projection Inspection
1. Hold a straight edge
!
along the top edge of the
cylinder liner to be measured.
2. Use a feeler gauge
"
to measure each cylinder line
projection.
The difference in the cylinder liner projection height
between any two adjacent cylinders must not exceed
0.03 mm (0.0012 in).
Standard
mm (in)
0.0 - 0.1 (0.0000 - 0.0039)
Flatness
1. Remove the cylinder body dowel.
2. Set the cylinder liner remover to the cylinder liner.
3. Check that the remover shaft ankle is firmly gripping
the cylinder liner bottom edge.
4. Slowly turn the remover shaft handle counterclockwise
to pull the cylinder liner free.
Cylinder Liner Remover Ankle: 5-8840-2304-0 (4JG2)
5-8840-2039-0
(4JB1/4JB1T/4JB1TC)
NOTE:
Take care not to damage the cylinder body upper
during the cylinder liner removal procedure.
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6A – 58
GENERAL ENGINE MECHANICAL
5. Use a straight edge
!
and a feeler gauge
"
to
measure the four sides and the two diagonals of the
cylinder body upper face.
If the measured values exceeds the limit, the cylinder
body must be replaced.
Cylinder Liner Bore Measurement
Use a cylinder indicator to measure the cylinder liner bore
at measuring point
!
in the thrust
"
-
"
and axial
#
direction of the crankshaft.
Measuring Point
!
20mm (0.79 in)
If the measured value exceeds the specified limit, the
cylinder liner must be replaced.
NOTE:
The inside of the dry type cylinder liner is chrome
plated. It cannot be rebored or honed.
If the inside of the cylinder liner is scored or
scorched, the cylinder liner must be replaced.
Cylinder Liner Grade Selection
Measure the cylinder body inside diameter and select the
appropriate cylinder liner grade.
Standard Lifting Interference
mm (in)
0.01 - 0.019 (0.0004 - 0.0007)
If the cylinder liner fitting interference is too small, engine
cooling efficiency will be adversely effected.
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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GENERAL ENGINE MECHANICAL 6A – 59
Cylinder Body Bore Measurement
1) Take measurements at measuring point (A) across
positions
!
-
!
,
"
-
"
,
#
-
#
, and
$
-
$
.
Measuring Point (A) 98mm (3.86 in).
2) Calculate the average value of the four measurements
to determine the correct cylinder grade.
3) Consult the following table with the resultant diameter
for the correct liner application.
Selection method of cylinder liner and piston grade for
service parts.
The production line stamped cylinder liner grade on the
top of cylinder body, the cylinder liner outside diameter
grade 1, 2, 3, 4.
If you find cylinder liner outside diameter grade 1 and
piston outside diameter B on the cylinder body or result of
measurement for each parts, you will select service parts
grade for cylinder liner 1, AX grade and for piston AX
grade.
The stamping grade code on the service parts are;
For cylinder liner grade stamped on the outside of cylinder
liner.
For piston grade stamped on the head of piston.
4JB1 / 4JB1T / 4JB1TC
mm (in)
Liner
outside
Grade
Cylinder bore
diameter average
Liner outside
diameter
Liner
bore
Grade
Service liner bore measurement
AX
93.035 (3.6628) - 93.050 (3.6634)
1
95.001 - 95.010
(3.7402 - 3.7406)
95.011 - 95.020
(3.7406 - 3.7409)
CX
93.051 (3.6634) - 93.066 (3.6640)
AX
93.035 (3.6628) - 93.050 (3.6634)
2
95.011 - 95.020
(3.7406 - 3.7409)
95.021 - 95.030
(3.7410 - 3.7413)
CX
93.051 (3.6634) - 93.066 (3.6640)
AX
93.035 (3.6628) - 93.050 (3.6634)
3
95.021 - 95.030
(3.7410 - 3.7413)
95.031 - 95.040
(3.7414 - 3.7417)
CX
93.051 (3.6634) - 93.066 (3.6640)
AX
93.035 (3.6628) - 93.050 (3.6634)
4
95.031 - 95.040
(3.7414 - 3.7417)
95.041 - 95.050
(3.7418 - 3.7421)
CX
93.051 (3.6634) - 93.066 (3.6640)
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