engine ISUZU KB P190 2007 Workshop Repair Manual

Engine Mechanical – V6 Page 6A1–318
Page 6A1–318
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 – 594
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 – 595
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 – 596

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–319
Page 6A1–319
12 Spray a commercially available thread cleaner into
the tapped hole.

Figure 6A1 – 597
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 – 598
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 – 599

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–320
Page 6A1–320
15 Install the insert (2) onto the driver installation tool (1).

Figure 6A1 – 600
16 Apply thread lock sealant (1) such as Loctite 277® or equivalent to the insert OD threads (2).

Figure 6A1 – 601
17 Install the insert and insta llation 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 – 602

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–321
Page 6A1–321
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 dr iver installation tool (1)
aligns with the surface of the engine block deck (2).
22 Inspect the insert for co rrect installation into the
tapped hole.

Figure 6A1 – 603

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–322
Page 6A1–322
4.9 Thread Repair Specifications
Left-hand Cylinder Head Camshaft Cover Face

Figure 6A1 – 604
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

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–323
Page 6A1–323
Left-hand Cylinder Head Front Face

Figure 6A1 – 605
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

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–324
Page 6A1–324
Left-hand Cylinder Head Intake Face

Figure 6A1 – 606
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


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–325
Page 6A1–325
Left-hand Cylinder Head Exhaust Face

Figure 6A1 – 607
Legend Hole Tool Number J 42385 Max. Depth in mm
Number Thread Size Drill Counter-
bore Tap Driver Insert Drill Tap
1 M10 x 1.5 211 212 213 214 215 33.5 27.0
2 M12 x 1.5 705 706 707 708 709 27.5 13.0
3 M6 x 1.0 201 202 203 204 205 22.5 18.0
4 M8 x 1.25 206 207 208 209 210 28.5 23.0


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–326
Page 6A1–326
Left-hand Cylinder Head Rear Face

Figure 6A1 – 608
Legend Hole Tool Number J 42385 Max. Depth in mm
Number Thread Size Drill Counter-
bore Tap Driver Insert Drill Tap
1 M10 x 1.5 211 212 213 214 215 33.5 27


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–327
Page 6A1–327
Right-hand Cylinder Head Camshaft Cover Face

Figure 6A1 – 609
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 Thru Thru
2 M6 x 1.0 701 n/a 203 204 205 28.5 24.0
3 M20 x 1.5 715 716 717 718 719 25.0 17.0
4 M6 x 1.0 201 202 203 204 205 22.5 18.0


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007