Isuzu N-Series. Manual — part 500
Engine Mechanical (4HK1-TC) 6A-105
• Apply engine oil on the piston pin. Use your
finger to push it in hole of the piston and rotate
it. If the pin smoothly rotates without instability,
the clearance is normal. If there is instability,
measure the clearance. If the clearance
exceeds the limit, replace the piston and the
piston pin.
11. Remove the bush.
• Set the collar, connecting rod and collar on the
setting bar as shown in the drawing.
• Tighten the nut.
Legend
1. Setting Bar
2. Connecting Rod
3. Nut
4. Collar
5. Bush
6. Collar
• Place the connecting rod bush replacer base on
press, tighten the fixation bolt.
• Use the bench press to replace the bush.
Special tool
Connecting rod bush replacer: 5-8840-2340-0
(EN-47682)
Legend
1. Bolt
2. Connecting Rod Bush Replacer
12. Measure the connecting rod alignment.
• Use a connecting rod aligner to measure the
parallelism of the big end hole and the small
end hole. If the measured value exceeds the
limit, replace it.
Piston pin and piston pin hole clearance
mm (in)
Standard
0.004 – 0.017 (0.00016 – 0.00067)
Limit
0.04 (0.0016)
N6A6199E
Connecting rod alignment
(par length of 100 mm (3.94 in))
mm (in)
Standard
Limit
Distortion and
Parallelism
0.05 (0.002)
0.20
(0.008)
N6A6200E
N6A6201E
6A-106 Engine Mechanical (4HK1-TC)
13. Measure the bearing oil clearance.
• Measure the oil clearance between the
connecting rod bearing and the crank pin with
the following method.
- Remove the connecting rod cap. Sort the
removed caps according to the cylinder
number.
- Clean the bearing and the shaft pin.
- Inspect the bearing. If it is damaged or worn
seriously, replace the entire bearing.
• Place the plastigauge on the crankshaft pin.
• Install the bearing cap and tighten the bolt with
the designated torque.
Apply molybdenum disulfide on the screw part
and the bearing surface.
Tighten:
Connecting rod bearing cap bolt to
1st step: 39 N
⋅m (4.0 kg⋅m/29 lb⋅ft)
2nd step: 60
° (degrees)
3rd step: 30
° (degrees)
Caution:
Do not rotate the crankshaft.
- Remove the cap.
- Measure the largest width of the plastigauge
to calculate the oil clearance. If the
clearance exceeds the limit, replace the
entire bearing.
- Remove the plastigauge from the bearing
and crankpin.
14. Select the connecting rod bearing.
• Select bearings carefully by the grade of big
end hole diameter of the connecting rod
according to the selection table.
Legend
1. Top and Back Recognition Boss
2. Big End Diameter Grade Mark
3. Cylinder Number
Bearing selection table
Crankpin and bearing clearance
mm (in)
Standard
0.037 – 0.077 (0.0015 – 0.0030)
Limit
0.10 (0.0039)
N6A6202E
Big end hole
diameter
Grade
Bearing
recognition
color
Oil clearance
mm (in)
A
Green
0.037 – 0.077
(0.0015 – 0.0030)
B
Yellow
0.037 – 0.077
(0.0015 – 0.0030)
N6A6203E
1
1
2
3
N6A6648E
Engine Mechanical (4HK1-TC) 6A-107
Legend
1. Grade Recognition Color
Reassembly
1. Install the bush
• Place the connecting rod bush replacer base on
a press, set the connecting rod and tighten the
fixation bolt.
Special tool
Connecting rod bush replacer: 5-8840-2340-0
(EN-47682)
Legend
1. Bolt
2. Connecting Rod Bush Replacer
• Set the collar, new bush and collar on the
setting bar as shown in the drawing.
• Tighten the nut.
• Adjust the oil hole of the connecting rod and the
oil hole of the bush, and use the bench press to
install the bush.
Legend
1. Setting Bar
2. Connecting Rod
3. Nut
4. Collar
5. Bush
6. Collar
• After installing the new bush, use a grinder to
machine the pin hole so that the pin clearance
equals the standard value.
2. Install the piston.
3. Install the connecting rod.
• Install it so that the front mark of the head of the
piston and the connecting rod forging mark
(projecting) on the connecting rod face the
same direction.
N6A6205E
N6A6200E
N6A6199E
N6A6206E
6A-108 Engine Mechanical (4HK1-TC)
• Use snap ring pliers to install the snap ring of
one side.
Legend
1. Front Mark
2. Forging Mark (Projecting)
4. Apply enough engine oil on the piston pin, push it
in the piston and the connecting rod small edge.
5. Use snap ring pliers to install the snap ring.
Caution:
Make sure that the snap ring is installed in the ring
groove properly. Make sure that the connecting rod
moves smoothly.
6. Use ring pliers to install the piston ring.
• Install the oil ring so that the joint angle of the
ring and coil expander is in the opposite 180
°
direction.
• Install 2nd and 1st compression rings in this
order so that the marks “2T” and “1T” face
upward.
Legend
1. Oil ring
2. Compression Ring 2nd
3. Compression Ring 1st
Caution:
Note that the shapes of compression rings 1st and 2nd
are different.
Make sure that there is no gap in the position indicated
in the drawing when the oil ring coil expander was
installed.
Installation
1. Install the connecting rod bearing.
• Install the bearing on the connecting rod, apply
engine oil on the bearing.
2. Install the piston and connecting rod assembly.
1
2
N6A6645E
N6A6208E
N6A6209E
N6A6210E
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