Isuzu KB P190. Manual - part 219

 

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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. 

012RY00013

012RY00014

012R300001

6A – 72  ENGINE MECHANICAL 

 

  

 

012RY00022 

 

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". 

 

012RY00017

012RY00018

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. 

 

 

 

 

 

 

 

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