ISUZU KB P190 2007 Workshop Repair Manual

Engine Mechanical – V6 Page 6A1–242

5 Install the left-hand side M20 oil gallery threaded plug
(1) and tighten to the correct torque specification.




Left-hand side M20 cylinder block
oil gallery threaded plug
torque specification .................................27.0 – 35.0 Nm
Figure 6A1 – 454
6 Install the left-hand side M14 coolant drain threaded plug (1) and tighten to the correct torque specification.




Left-hand side M14 cylinder block
coolant drain threaded plug
torque specification .................................27.0 – 35.0 Nm
Figure 6A1 – 455
7 Install the M14 rear oil gallery threaded plug (1) and tighten to the correct torque specification.




M14 cylinder block rear oil gallery
threaded plug torque specification ..........27.0 – 35.0 Nm

Figure 6A1 – 456

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Engine Mechanical – V6 Page 6A1–243

8 Install the right-hand side M14 coolant drain threaded
plug (1) and tighten to the correct torque specification.




Right-hand side M14 cylinder block
coolant drain threaded plug
torque specification .................................27.0 – 35.0 Nm

Figure 6A1 – 457
9 Install the right-hand side M14 oil gallery threaded plug (1) and tighten to the correct torque specification.




Right-hand side M14 cylinder block
oil gallery threaded plug
torque specification .................................27.0 – 35.0 Nm

Figure 6A1 – 458
10 Install the cylinder block-to-oil pan alignment dowels (1).

Figure 6A1 – 459

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Engine Mechanical – V6 Page 6A1–244

11 Install the new right-hand front oil pan rail oil gallery
expansion plug (1).

Figure 6A1 – 460
12 Install the oil jet (2), three places.

13 Install the oil jet attaching bolt (1), three places and tighten to the correct torque specification.



Oil jet attaching bolt
torque specification ...................................8.0 – 12.0 Nm

Figure 6A1 – 461
4.8 Thread Repairs
General Information
The thread repair process involves a solid, thin walled, self-locking, carbon steel, bushing type insert. During the insert
installation process, the installation driver tool cold-rolls the bottom internal threads and expands the bottom external
threads of the insert into the base material. This action mechanically locks the insert into place.
This Section describes the recommended method of repairing threads in three specific areas of the engine.
• general thread repair,
• cylinder block main bearing cap bolt hole thread repair, and
• cylinder head bolt hole thread repair.
For detailed descriptions of all thread specifications used refer to 4.9 Thread Repair Specifications.
The drill-bit and counter-bore tool from the thread repair kit, Tool No. J-42385-700 and J-42385-2000 are designed for
use with either a suitable tap wrench or drill motor. Limited access and larger hole repair may process better using a tap
wrench. An extension from Tool J 43965 may also be required to drive the thread repair tooling dependent on access to
the hole being repaired. Use only a tap wrench when tapping the hole and during installation of the insert.

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–245

1 It is critical the drilling, counter boring and tapping of
the hole to be repaired follows the same centreline (1)
as the original hole.
Figure 6A1 – 462
2 During the drilling and tapping of the hole being repaired, ensure the tooling is consistently machining
perpendicular to the surface of the base material.
Figure 6A1 – 463
3 If the threaded hole being repaired has a base surface perpendicular to the hole centreline, tapping
guides are available to aid in tapping the hole.


Tap
Size Tap
Guide Tap
Size Tap
Guide Tap
Size Tap
Guide
- J 42385 - J
42385 - J
42385
6 x 1.0 729 10 x
1.5 731 14 x
1.5 736
8 x
1.25 730 12 x
1.5 732 20 x
1.5 737

Figure 6A1 – 464

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Engine Mechanical – V6 Page 6A1–246

General Thread Repair
NOTE
The use of a cutting type fluid such as WD 40® or
equivalent is recommended when performing the
drilling, counter boring and tapping procedures
1 W hen installed to the correct depth, the flange (1) of the insert will be seated against the counter bore of
the drilled/tapped hole and just below the surface (2)
of the base material.


Figure 6A1 – 465
NOTE
During the drilling process, repeatedly remove
the drill and clean the swarf from the hole and
the flutes of the drill.
CAUTION
Do not drill any further than the original hole
depth.
2 Drill out the threads of the damaged hole to the correct depth for the thread being repaired:
• M6 inserts require a minimum drill depth of 15
mm.
• M8 inserts require a minimum drill depth of 20
mm.
• M10 inserts require a minimum drill depth of
23.5 mm.

Figure 6A1 – 466
NOTE
All swarf must be removed from the drilled hole
prior to tapping.

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

Figure 6A1 – 467

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Engine Mechanical – V6 Page 6A1–247

NOTE
A correctly counter bored hole will show a slight
burnishing on the surface of the base material
for 360 degrees around the drilled hole.
4 Counter bore the drilled hole to the full depth permitted by the tool (1).

Figure 6A1 – 468
NOTE
All swarf must be removed from the drilled hole
prior to tapping.


Safety glasses must be worn when using
compressed air.
5 Using compressed air, clean out any swarf.
Figure 6A1 – 469
NOTE
• During the tapping process, 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.
6 Using a suitable tapping wrench, tap the threads of the drilled hole by hand only.
• M6 inserts require a minimum drill depth of 15
mm.
• M8 inserts require a minimum drill depth of 20
mm.
• M10 inserts require a minimum drill depth of
23.5 mm.
Figure 6A1 – 470

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Engine Mechanical – V6 Page 6A1–248

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

Safety glasses must be worn when using
compressed air.
7 Using compressed air, clean out any swarf.
Figure 6A1 – 471
8 Spray a commercially available thread cleaner into the tapped hole.
Figure 6A1 – 472
NOTE
All swarf must be removed from the tapped hole
prior to insert installation.

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

Figure 6A1 – 473

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Engine Mechanical – V6 Page 6A1–249

NOTE
Do not allow oil or other foreign material to
contact the outside diameter (OD) of the insert.
10 Lubricate the threads of the driver installation tool (2) with the driver oil (1).
Figure 6A1 – 474
11 Install the insert (2) onto the driver installation tool (1).

Figure 6A1 – 475
12 Apply thread lock sealant (1) such as Loctite 277® or equivalent to the insert OD threads (2).
Figure 6A1 – 476

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Engine Mechanical – V6 Page 6A1–250

13 Install the insert (2) into the tapped hole by hand only.

Figure 6A1 – 477
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 the flange (2) of the insert contacts the counter bore surface.
Figure 6A1 – 478
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 – 479

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Engine Mechanical – V6 Page 6A1–251

17 Inspect the insert for correct 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 – 480
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 coolant passage. After drilling
the restriction or blockage, 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 – 481
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 – 482

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