ISUZU KB P190 2007 Workshop Repair Manual

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

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

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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

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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

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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

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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

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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

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ISUZU KB P190 2007