Page 1212 of 4264
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)
Page 1213 of 4264
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
Page 1214 of 4264
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.
Page 1215 of 4264
ENGINE MECHANICAL 6A – 75
2. Measure the piston diameter.
Piston Measuring Point mm (in)
4JA1T(L)
4JA1TC 78 (3.07)
4JH1TC 70 (2.76)
Piston Grade (Service Part) mm (in)
AX 92.949 - 92.964
(3.6549 - 3.6600)
4JA1T(L)
4JA1TC
CX 92.965 - 92.980
(3.6600 - 3.6606)
AX 95.359 - 95.374
(3.7542 - 3.7548)
4JH1TC
CX 95.375 - 95.390
(3.7548 - 3.7555)
Cylinder Liner and Piston Clearance mm (in)
4JA1T(L)
4JA1TC 0.041-0.071 (0.0016-0.0027)
4JH1TC 0.047-0.065 (0.0019-0.0026)
NOTE:
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.
TAPPET AND PUSH ROD
Visually inspect the tappet contact surfaces for pitting,
cracking, and other abnormal conditions. The tappet must be
replaced if any of these conditions are present.
Refer to the illustration at the left.
1. Normal contact
2. Cracking
3. Pitting
4. Irregular contact Uneven contact
5. Irregular contact One-sided contact
NOTE:
The tappet surfaces are spherical. Do not attempt to
grind them with an oil stone or similar tool in an effort
to repair the tappet. If the tappet is damaged, it must
be replaced.
015LX021
014RY00028
Page 1219 of 4264
ENGINE MECHANICAL 6A – 79
CRANKSHAFT AND BEARING
Inspect the surface of the crankshaft journals and crankpins for
excessive wear and damage.
Inspect the oil seal fitting surfaces for excessive wear and
damage.
Inspect the oil ports for obstructions.
NOTE:
To increase crankshaft strength, tufftriding (Nitrizing
Treatment) has been applied. Because of this, it is not
possible to regrind the crankshaft surfaces.
Therefore, under size bearing are not available.
Crankshaft Run-Out
1. Set a dial indicator to the center of the crankshaft journal.
2. Gently turn the crankshaft in the normal direction of
rotation.
Read the dial indicator as you turn the crankshaft.
If the measured value exceeds the specified limit, the
crankshaft must be replaced.
Crankshaft Run-Out mm (in)
Standard Limit
0.05 (0.002) or less 0.08 (0.003)
Bearing Spread
Use a vernier caliper to measure the bearing spread.
If the measured value is less than the specified limit, the
bearing must be replaced.
Bearing Spread mm (in)
Limit
4JA1T (L),
4JA1TC 64.5 (2.54)
Creankshaft Bearing
4JH1TC 74.5 (2.93)
Connecting Rod Bearing 56.5 (2.22)
015LX061
015RY00007
Page 1220 of 4264
6A – 80 ENGINE MECHANICAL
Crankshaft Journal and Crankpin Diameter
1. Use a micrometer to measure the crankshaft journal
diameter across points 1 - 1 and 2 - 2.
2. Use the micrometer to measure the crankshaft journal
diameter at the two points (3 and 4).
3. Repeat Steps 1 and 2 to measure the crankpin diameter.
If the measured values are less than the specified limit, the
crankshaft must be replaced.
Crankshaft Journal and Diameter mm (in)
Standard Limit
4JA1T (L),
4JA1TC 59.921-59.928
(2.3591-2.3594) 59.91 (2.3586)
4JH1TC 69.917-69.932
(2.7526-2.7532) 69.91(2.7524)
Crankpin Diameter mm (in)
Standard Limit
52.915 - 52.930
(2.0833 - 2.0839) 52.90 (2.083)
Crankshaft Journal and Crankpin Uneven Wear mm (in)
Standard Limit
0.05 (0.002) or less 0.08 (0.003)
Crankshaft Journal and Crankpin Diameter
If the clearance between the measured bearing inside diameter
and the crankshaft journal diameter exceeds the specified limit,
the bearing and/or the crankshaft must be replaced.
Crankshaft Journal and Bearing Clearance mm (in)
Standard Limit
0.032 - 0.077
(0.0013 - 0.0030) 0.110 (0.0043)
015RY00008
015RY00009
Page 1221 of 4264
ENGINE MECHANICAL 6A – 81
Connecting Rod Bearing Inside Diameter
1. Install the bearing to the connecting rod big end.
2. Tighten the bearing cap to the two step of anglar tightening
method.
Connecting Rod Bearing Cap Bolt Torque N·m (kg·m/Ib ft)
4JA1T (L),
4JA1TC 78-88 (8.0/57 – 9.0/65)
1st step ; 29.0–29.2 (3.00/22.0–3.01/22.2)4JH1TC
2nd step ; 45-60
3. Use an inside dial indicator to measure the connecting rod
bearing inside diameter.
Crankpin and Bearing Clearance
If the clearance between the measured bearing inside diameter
and the crankpin exceeds the specified limit, the bearing
and/or the crankshaft must be replaced.
Crankpin and Bearing Clearance mm (in)
Standard Limit
4JA1T (L),
4JA1TC 0.029-0.066
(0.0011-0.0026) 0.100(0.0039)
4JH1TC 0.029-0.083
(0.0011-0.033) 0.100 (0.0039)
Clearance Measurements (With Plastigage)
Crankshaft Journal and Bearing Clearance
1. Clean the cylinder body, the journal bearing fitting surface,
the bearing caps, and the bearings.
2. Install the bearings to the cylinder body.
3. Carefully place the crankshaft on the bearings.
4. Rotate the crankshaft approximately 30 to seat the
bearing.
5. Place the Plastigage (arrow) over the crankshaft journal
across the full width of the bearing.
6. Install the bearing caps with the bearing.
7. Tighten the bearing caps to the specified torque.
Crankshaft Bearing Cap Bolt Torque mm (in)
167 (17/123)
Do not allow the crankshaft to turn during bearing cap
installation and tightening.
8. Remove the bearing cap.
015RY00012
015RY00013 015RY00011
Page 1222 of 4264
6A – 82 ENGINE MECHANICAL
9. Compare the width of the Plastigage attached to either the
crankshaft or the bearing against the scale printed on the
Plastigage container.
If the measured value exceeds the limit, perform the
following additional steps.
1. Use a micrometer to measure the crankshaft outside
diameter.
2. Use an inside dial indicator to measure the bearing
inside diameter.
If the crankshaft journal and bearing clearance
exceeds the limit, the crankshaft and/or the bearing
must be replaced.
Crankshaft Journal and Bearing Clearance mm (in)
Standard Limit
0.032 - 0.077
(0.0013 - 0.0030) 0.110 (0.0043)
Crankpin and Bearing Clearance
1. Clean the crankshaft, the connecting rod, the bearing cap,
and the bearings.
2. Install the bearing to the connecting rod and the bearing
cap.
Do not allow the crankshaft to move when installing the
bearing cap.
3. Prevent the connecting rod from moving.
4. Attach the Plastigage to the crankpin.
Apply engine oil to the Plastigage to keep it from falling.
5. Install the bearing cap and tighten it to the two step of
anglar tihtening method.
Do not allow the connecting rod to move when installing
and tightening the bearing cap.
Connecting Rod Bearing Cap Bolt Torque N·m (kg·m/Ib ft)
4JA1T (L),
4JA1TC 78-88 (8.0/57 – 9.0/65)
1st step ; 29.0–29.2 (3.00/22.0–3.01/22.2)4JH1TC
2nd step ; 45-60
015LX129
015LX060
