engine ISUZU KB P190 2007 Workshop Repair Manual

Engine Mechanical – V6 Page 6A1–256

15 Apply thread lock sealant (1) such as Loctite 277® or
equivalent to the insert OD threads (2).
Figure 6A1 – 494
16 Install the insert and installation driver (1) to the tapped hole by hand only.
17 Start the insert into the threaded hole.
CAUTION
If the insert will not thread down until the
flange contacts the counter-bored surface,
remove the insert immediately with a screw
extracting tool and inspect the tapped hole
for any remaining swarf and/or incorrect
tapping.
18 Install the insert until the flange of the insert contacts the counter-bored surface.
NOTE
The driver installation tool will tighten up before
cutting completely through the insert. This is
acceptable. The threads at the bottom of the
insert are being formed and the insert is
mechanically locking the insert into the base
material threads.
19 Continue to rotate the driver installation tool through the insert.
Figure 6A1 – 495
20 Rotate the driver installation tool until the mark (1) on the driver installation tool aligns with the top of the
drill bushing (2).
21 Inspect the insert for correct installation into the tapped hole.
Figure 6A1 – 496

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–257

22 Remove the fixture plate bolts (1), bushing (2) and
fixture plate (3).
Figure 6A1 – 497
Cylinder Head Bolt Hole Thread Repair
The cylinder head bolt hole thread repair tools are in Tool
No. J 42385-2000 and J 42385-700 which consist of the
following:
• Drill (1) J 42385-723
• Tap (2) J 42385-724
• Installation driver (3) J 42385-725
• Alignment pin (4) J 42385-303
• Bushing (5) J 42385-302
• Bolts (6) J 42385-733
• Fixture plate (7) J 42385-401
Figure 6A1 – 498
NOTE
• Ensure the fixture plate is installed during the
machining and installation processes of the
insert.
• The use of a cutting type fluid such as
WD 40® or equivalent is recommended when
performing the drilling, counter boring and
tapping procedures.
• When installed to the correct depth, the flange
of the insert will be seated against the counter
bore of the drilled/tapped hole.

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–258

1 Position the fixture plate (3) with the bushing (1)
installed over the cylinder head bolt hole to be
repaired (4).
2 Loosely install the fixture plate bolts (2) into the remaining cylinder head bolt holes.
Figure 6A1 – 499
3 Position the alignment pin (1) through the bushing and into the cylinder head bolt hole.
4 W ith the alignment pin in the desired cylinder head bolt hole, tighten the fixture retaining bolts (2).
5 Remove the alignment pin.
Figure 6A1 – 500
NOTE
During the drilling process, repeatedly remove
the drill and clean swarf from the hole and the
flutes of the drill.
6 Drill the hole until the stop collar contacts the top of the drill bushing.
Figure 6A1 – 501

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–259

NOTE
All swarf must be removed from the drilled hole
prior to tapping.

Safety glasses must be worn when using
compressed air.
7 Using compressed air, clean out any swarf.
Figure 6A1 – 502
CAUTION
Do not remove the fixture plate during the
machining and installation processes of the
insert.
NOTE
• During the tapping process, repeatedly
remove the tap and clean swarf from the
hole and the flutes of the tap.
• Ensure the tap has created full threads at
least to the depth equal to the insert length.
8 Using a suitable tapping wrench, tap the threads of the drilled hole by hand only.
Figure 6A1 – 503
9 In order to tap the new threads for the insert to the correct depth, rotate the tap into the cylinder head
bolt hole until the mark (1) on the tap aligns with the
top of the drill bushing (2).
Figure 6A1 – 504

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–260

NOTE
Remove the fixture plate prior to installing the
insert with the installer tool.
10 Remove the bushing (1) and fixture plate bolts (2) from the cylinder block (4) and remove the fixture
plate (3).
Figure 6A1 – 505
NOTE
All swarf must be removed from the tapped hole
prior to insert installation.

Safety glasses must be worn when using
compressed air.
11 Using compressed air, clean out any swarf.
Figure 6A1 – 506
12 Spray a commercially available thread cleaner into the tapped hole.
Figure 6A1 – 507

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–261

NOTE
All swarf must be removed from the tapped hole
prior to insert installation.

Safety glasses must be worn when using
compressed air.
13 Using compressed air, clean out any swarf.
Figure 6A1 – 508
NOTE
Do not allow oil or other foreign material to
contact the outside diameter (OD) of the insert.
14 Lubricate the threads of the driver installation tool (2) with the driver oil (1).
Figure 6A1 – 509
15 Install the insert (2) onto the driver installation tool (1).
Figure 6A1 – 510

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–262

16 Apply thread lock sealant (1) such as Loctite 277® or
equivalent to the insert OD threads (2).
Figure 6A1 – 511
17 Install the insert and installation driver (1) into the tapped hole by hand only.
18 Start the insert into the threaded hole.
CAUTION
If the insert will not thread down until the
flange contacts the counter-bored surface,
remove the insert immediately with a screw
extracting tool and inspect the tapped hole
for any remaining swarf and/or incorrect
tapping.
19 Install the insert until the flange of the insert contacts the counter-bored surface.
NOTE
The driver installation tool will tighten up before
cutting completely through the insert. This is
acceptable. The threads at the bottom of the
insert are being formed and the insert is
mechanically locking the insert into the base
material threads.
20 Continue to rotate the driver installation tool through the insert.
Figure 6A1 – 512
21 In order to completely form the new threads in the insert, rotate the driver installation tool through the
insert until the mark on the driver installation tool (1)
aligns with the surface of the engine block deck (2).
22 Inspect the insert for correct installation into the tapped hole.
Figure 6A1 – 513

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–263

4.9 Thread Repair Specifications
Left-hand Cylinder Head Camshaft Cover Face

Figure 6A1 – 514
Legend Hole Tool Number J 42385 Max. Depth in mm
Number Thread Size Drill Counter-
bore Tap Driver Insert Drill Tap
1 M6 x 1.0 201 202 203 204 205 22.5 18.0
2 M6 x 1.0 201 202 203 204 205 Thru Thru
3 M6 x 1.0 701 n/a 203 204 205 28.5 24.0
4 M20 x 1.5 715 716 717 718 719 25.0 17.0

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–264

Left-hand Cylinder Head Front Face

Figure 6A1 – 515
Legend Hole Tool Number J 42385 Max. Depth in mm
Number Thread Size Drill Counter-
bore Tap Driver Insert Drill Tap
1 M8 x 1.25 206 207 208 209 210 Thru Thru
2 M12 x 1.75 856 857 858 859 416 40.0 32.5
3 M8 x 1.25 206 207 208 209 210 22.5 18.0

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–265

Left-hand Cylinder Head Intake Face

Figure 6A1 – 516
Legend Hole Tool Number J 42385 Max. Depth in mm
Number Thread Size Drill Counter-
bore Tap Driver Insert Drill Tap
1 M8 x 1.25 206 207 208 209 210 28.5 23.0


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ISUZU KB P190 2007