lock ISUZU KB P190 2007 Workshop Repair Manual

Engine Mechanical – V6 Page 6A1–240

2 Calculate the difference between the two measurements. The result will indicate out-of-round at the upper end of
the cylinder.
3 Measure both the thrust and non-thrust cylinder diameter at 100 mm below the deck surface. Record your measurements.
4 Calculate the difference between the two measurements. The result will indicate out-of-round at the lower end of the cylinder.
5 Compare your results with the dimensions listed in the specifications, refer to 5 Specifications.
NOTE
If the cylinder diameter exceeds the
specifications, the cylinder block may be
oversized to 0.25 mm. Only one size of oversized
pistons and rings are available for service. If the
cylinder bore diameter exceeds specification by
more than 0.25 mm, the cylinder block must be
replaced.
Deck Flatness Inspection
1 Ensure the engine block decks are clean and free of gasket material.
2 Inspect the surface for any imperfections or scratches that could inhibit correct cylinder head gasket sealing.
3 Place a straight-edge diagonally across the cylinder block deck face surface.
4 Measure the clearance between the straight-edge and the cylinder block deck face using a feeler gauge
at 4 points along the straight-edge.
5 If the warpage is less than 0.05 mm, the cylinder block deck surface does not require resurfacing.
6 If the warpage is between 0.05 ±0.20 mm or any imperfections or scratches that could inhibit correct
cylinder head gasket sealing are present, the cylinder
block deck surface requires resurfacing.
7 If resurfacing is required the maximum amount that can be removed is 0.25 mm.
8 If the cylinder block deck surface requires more than 0.25 mm material removal the block must be
replaced.
Figure 6A1 – 449
Reassemble
1 Install the cylinder block-to-cylinder head alignment
dowels (1).
Figure 6A1 – 450

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–241

2 Install a new front oil gallery expansion plug (1).
Figure 6A1 – 451
3 Install the cylinder block-to-transmission alignment dowels (1).
Figure 6A1 – 452
4 Place RTV sealant on new coolant expansion plugs (1) and install the new coolant expansion plugs.
Figure 6A1 – 453

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

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

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

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

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

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.

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

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

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

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

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

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

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

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

BACK TO CHAPTER INDEX
TO MODEL INDEX
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

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007