engine ISUZU KB P190 2007 Workshop Repair Manual

Engine Mechanical – V6 Page 6A1–308
Page 6A1–308
12 Apply thread lock sealant (1) such as Loctite 277® or
equivalent to the insert OD threads (2).

Figure 6A1 – 566
13 Install the insert (2) into the tapped hole by hand only.


Figure 6A1 – 567
CAUTION
If the insert will not thread down until the
flange contacts the counter bore surface,
remove the insert immediately with a screw
extracting tool and inspect the tapped hole
for any remaining swarf and/or incorrect
tapping.
14 Install the insert until t he flange (2) of the insert
contacts the count er bore surface.

Figure 6A1 – 568

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–309
Page 6A1–309
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.
15 Continue to rotate the driver installation tool (1) through the insert (2)
16 Remove the driver installation tool.

Figure 6A1 – 569
17 Inspect the insert for co rrect installation into the
tapped hole. A correctly installed insert (1) will be
either flush or slightly below flush with the surface of
the base material (2).

Figure 6A1 – 570
18 Any installed insert that restricts or blocks an oil or
engine coolant passage (3) will need to have the oil or
engine coolant passage drilled out (4) to the original
size of the oil or engine c oolant passage. After drilling
the restriction or block age, clean out any swarf and
thread the installation driver tool through the insert
again to remove any burrs caused by the drilling of
the oil or engine coolant passage.

Figure 6A1 – 571

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–310
Page 6A1–310
Main Bearing Cap Bolt Hole Thread Repair
The crankshaft main bearing bolt hole thread repair tools
are in Tool No. J 42385-2000 and J 42385-700 which
consist of the following:
• Drill (1) for outboard holes J 42385-702
• Tap (2) for outboard holes J 42385-703
• Installation driver (3) for outboard holes J 42385-704
• Bushing (4) for outboard holes J 42385-726
• Alignment pin (5) for outboard holes J 42385-727
• Bolts (6) for outboard holes J 42385-728
• Drill (7) for inboard holes J 42385-720
• Tap (8) for inboard holes J 42385-721
• Installation driver (9) for inboard holes J 42385-722
• Bushing (10) J 42385-713
• Alignment pin (11) J 42385-308
• Bolts (12) J 42385-734
• Fixture plate (13) J 42385-712

Figure 6A1 – 572
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 s eated against the counter
bore of the drilled/tapped hole.
1 Position the fixture plate (3) with the bushing (2) installed over the crankshaft main cap bolt hole to be
repaired.
2 Loosely install the fixture plate bolts (1) into the
remaining crankshaft main cap bolt holes.

Figure 6A1 – 573

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–311
Page 6A1–311
3 Position the alignment pin (1) through the bushing
and into the crankshaft main cap bolt hole.
4 With the alignment pin in the desired crankshaft main cap bolt hole, tighten the fixt ure retaining bolts (2).
5 Remove the alignment pin.

Figure 6A1 – 574
6 Drill the crankshaft main bolt hole until the mark (1) on the drill aligns with the top of the drill bushing (2).

NOTE
During the drilling process, repeatedly remove
the drill and clean the swarf from the hole and
the flutes of the drill.

Figure 6A1 – 575
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 – 576

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–312
Page 6A1–312
NOTE
• During the tapping pr ocess, repeatedly
remove the tap and clean the 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.
CAUTION
Do not remove the fixture plate during the
machining and installation processes of the
insert.
8 Using a suitable tapping wr ench, tap the threads of
the drilled hole by hand only.

Figure 6A1 – 577
9 In order to tap the new threads for the insert to the correct depth, rotate the t ap into the crankshaft main
cap bolt hole until the mark (1) on the tap aligns with
the top of the drill bushing (2).

Figure 6A1 – 578
NOTE
All swarf must be removed from the tapped hole
prior to insert installation.

Safety glasses must be worn when using
compressed air.
10 Using compressed air, clean out any swarf.

Figure 6A1 – 579

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–313
Page 6A1–313
11 Spray a commercially available thread cleaner into
the tapped hole.

Figure 6A1 – 580
NOTE
All swarf must be removed from the tapped hole
prior to insert installation.


Safety glasses must be worn when using
compressed air.
12 Using compressed air, clean out any swarf.

Figure 6A1 – 581
NOTE
• Do not remove the fixt ure plate, ensure the
fixture plate is in stalled during the
installation process of the insert.
• Do not allow oil or other foreign material to
contact the outside diam eter (OD) of the
insert.
13 Lubricate the threads of the driver installation tool (2)
with the driver oil (1).

Figure 6A1 – 582

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–314
Page 6A1–314
14 Install the insert (2) onto the driver installation tool (1).

Figure 6A1 – 583
15 Apply thread lock sealant (1) such as Loctite 277® or equivalent to the insert OD threads (2).

Figure 6A1 – 584
16 Install the insert and inst allation 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 – 585

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–315
Page 6A1–315
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 co rrect installation into the
tapped hole.

Figure 6A1 – 586
22 Remove the fixture plate bolts (1), bushing (2) and fixture plate (3).

Figure 6A1 – 587
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 – 588

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–316
Page 6A1–316
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 s eated against the counter
bore of the drilled/tapped hole.
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 – 589
3 Position the alignment pin (1) through the bushing and into the cylinder head bolt hole.
4 With the alignment pin in the desired cylinder head bolt hole, tighten the fixture retaining bolts (2).
5 Remove the alignment pin.

Figure 6A1 – 590

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–317
Page 6A1–317
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 co llar contacts the top of
the drill bushing.

Figure 6A1 – 591
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 – 592
CAUTION
Do not remove the fixture plate during the
machining and installation processes of the
insert.
NOTE
• During the tapping pr ocess, 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 wr ench, tap the threads of
the drilled hole by hand only.

Figure 6A1 – 593

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ISUZU KB P190 2007