Isuzu N-Series. Manual — part 333
6A-74 ENGINE MECHANICAL
Caution:
Check that the cylinder liner is set perpendicular to the
bench press and that there is no wobble.
• Use the bench press to apply a seating force of
4,900 N (500 kg / 1,102.5 lb) to the cylinder lin-
er.
• Apply a force of 24,500 N (2,500 kg / 5,512.5 lb)
to fully seat the cylinder liner.
• After installing the cylinder liner, measure the
cylinder liner projection.
Refer to “Cylinder Liner Projection Inspection”.
2. Cylinder Liner Installation Using Dry Ice
If the cylinder liner is a chrome plated dry type, it is
advisable to use dry ice during the installation pro-
cedure.
Cooling the cylinder liner with dry ice will cause the
cylinder liner to contract, thus making installation
easier.
Caution:
It is important that the cylinder liner be inserted to the
cylinder body immediately after it has been cooled.
Warning:
WARNING:
DRY ICE MUST BE USED WITH GREAT CARE.
CARELESS HANDLING OF DRY ICE CAN RESULT
IN SEVERE FROSTBITE.
Piston Grade Selection
Measure the cylinder liner bore after installing the cylin-
der liner. Then select the appropriate piston grade for
the installed cylinder liner.
1. Measure the cylinder liner bore.
Refer to the “Cylinder Liner Bore Measurement”.
Measuring Point (1) 20 mm (0.79 in)
Measuring Point (2) 90 mm (3.54 in)
Measuring Point (3) 160 mm (6.30 in)
Caution:
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.
2. Measure the piston outside diameter (Reference).
Piston Measuring Point (4): 82 mm (3.23 in)
N6A0302E
Cylinder Liner Bore
mm (in)
Standard
Limit
4HF1
4HF1-2
112.021 — 112.050
(4.4103 — 4.4114)
112.20 (4.417)
4HG1
4HG1-T
115.021 — 115.050
(4.5284 — 4.5295)
115.20 (4.535)
4HE1-TC
110.041 — 110.080
(4.3323 — 4.3338)
110.23 (4.340)
Cylinder Liner and Piston
Clearance
mm (in)
4HF1 / 4HF1-2: 0.081 — 0.113 (0.0032 — 0.0044)
4HG1 / 4HG1-T: 0.081 — 0.116 (0.0032 — 0.0046)
4HE1-TC: 0.091 — 0.131 (0.0036 — 0.0052)
N6A0306E
ENGINE MECHANICAL 6A-75
The piston grade (i.e. A, B, C) is indicated in metal
stamp on the piston upper face.
Caution:
Cylinder liner kit clearances are preset. However, the
cylinder liner installation procedure may result in slight
decreases in cylinder liner clearances. Always measure
the cylinder liner clearance after installation to be sure
that it is correct.
Reassembly
1. Cylinder Block
Use compressed air to thoroughly clean the inside
and outside surfaces of the cylinder body, the oil
holes, and the water jackets.
2. Piston Oiling Jet
1) Install the oiling jets together with the check
valves. Take care not to damage the oiling jet
nozzles.
2) Tighten the check valves and oiling jets to the
specified torque.
Tighten:
Check valve and oiling jet to 21 N
⋅m (2.1 kg⋅m / 15 lb⋅ft)
Piston Grade
Engine
Model
Cylinder Liner
Bore Diameter
mm (in)
Piston
Service
Grade
Piston Out-
side Diameter
mm (in)
4HF1
4HF1-2
112.041 —
112.060
(4.4111 —
4.4118)
—
111.944 —
111.959
(4.4072 —
4.4078)
4HG1
4HG1-T
115.041 —
115.060
(4.5292 —
4.5299)
—
114.944 —
114.959
(4.5253 —
4.5259)
4HE1-
TC
110.066 —
110.075
(4.3333 —
4.3337)
AX
109.944 —
109.959
(4.3285 —
4.3291)
110.076 —
110.085
(4.3337 —
4.3340)
CX
109.960 —
109.975
(4.3291 —
4.3297)
N6A0307E
Legend
1. Part No.
2. Grade
3. Front mark
N6A0308E
6A-76 ENGINE MECHANICAL
3. Crankshaft Bearing Upper
4. Thrust Bearing Upper
5. Crankshaft Assembly
6. Crankshaft Bearing Lower
7. Thrust Bearing Lower
8. Crankcase
Above works refer to “CRANKSHAFT” section in
this manual.
9. Piston and Connecting Rod Assembly
10. Connecting Rod Lower Bearing
11. Connecting Rod Cap
Above works refer to “PISTON AND CONNECT-
ING ROD” section in this manual.
12. Oil Pump Assembly
13. Idle Gear B Shaft
Tighten:
Idle gear B shaft bolt to 31 N
⋅m (3.2 kg⋅m / 23 lb⋅ft)
Apply the engine oil to the idle gear shaft after in-
stallation.
14. Idle Gear B
The face of the idle gear B with longer boss should be
positioned toward the rear side shown in the illustration.
Tighten:
Idle gear B bolt to 110 N
⋅m (11.2 kg⋅m / 81 lb⋅ft)
15. Idle Gear A
16. Flywheel Housing
17. Power Steering Pump Idle Gear
18. Power Steering Pump Idle Gear Cover
Above works refer to “OIL PUMP” section in this
manual.
19. Oil Thermo Valve
20. Front Retainer
Above works refer to “CRANKSHAFT” section in
this manual.
21. Water Pump Assembly
1) Apply 3 — 4 mm (0.12 — 0.16 in) bead of the
recommended liquid gasket (Three Bond
1207C) or its equivalent on the water pump fit-
ting surface.
2) Install the water pump to the front retainer.
Tighten:
Water pump bolt to 24 N
⋅m (2.4 kg⋅m / 17 lb⋅ft)
• Install the water pump within 7 minutes after
application of liquid gasket.
• For the dislocation of liquid gasket, refer to the
illustration.
N6A0296E
N6A0310E
N6A0311E
ENGINE MECHANICAL 6A-77
Caution:
The water pump clamping bolt is also used to tighten the
front retainer. So, install the water pump before liquid
gasket gets dry immediately after installation of the front
retainer.
22. Water Pump Pulley
Tighten:
Water pump pulley bolt to 24 N
⋅m (2.4 kg⋅m / 17 lb⋅ft)
23. Oil Pump Strainer
Install the O-ring (1) to the oil pump strainer pipe
and install the oil pump strainer to the cylinder body
shown in the illustration.
Tighten:
Oil pump strainer bolt to 24 N
⋅m (2.4 kg⋅m / 17 lb⋅ft)
24. Oil Pan
Above works refer to “OIL PAN” section in this
manual.
25. Spacer Rubber
Tighten:
Spacer rubber bolt to 76 N
⋅m (7.7 kg⋅m / 56 lb⋅ft)
26. Crankshaft Rear Slinger
27. Crankshaft Rear Oil Seal
28. Flywheel Assembly
29. Crankshaft Front Slinger
30. Crankshaft Front Oil Seal
31. Crankshaft Damper Pulley
Above works refer to “CRANKSHAFT” section in
this manual.
32. Cover
Tighten:
Cover Bolt to 13 N
⋅m (1.3 kg⋅m / 9 lb⋅ft)
Legend
1. Liquid gasket
Legend
1. Pulley
2. Set plate
N6A1625E
N6A0313E
N6A0314E
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