lock ISUZU KB P190 2007 Workshop Repair Manual

Engine Mechanical – V6 Page 6A1–301
Page 6A1–301
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 specif ication .......... 27.0 – 35.0 Nm


Figure 6A1 – 546
8 Install the right-hand side M14 coolant drain threaded
plug (1) and tighten to the co rrect torque specification.




Right-hand side M14 cylinder block
coolant drain threaded plug
torque specificatio n ................................. 27. 0 – 35.0 Nm


Figure 6A1 – 547
9 Install the right-hand side M14 oil gallery threaded plug (1) and tighten to the co rrect torque specification.




Right-hand side M14 cylinder block
oil gallery threaded plug
torque specificatio n ................................. 27. 0 – 35.0 Nm


Figure 6A1 – 548

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–302
Page 6A1–302
10 Install the cylinder block-to-oil pan alignment
dowels (1).


Figure 6A1 – 549
11 Install the new right-hand front oil pan rail oil gallery expansion plug (1).


Figure 6A1 – 550
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 specificatio n ................................... 8. 0 – 12.0 Nm


Figure 6A1 – 551

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–303
Page 6A1–303
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 dr iver 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 recomm ended 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 th read 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 hol e 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 dur ing installation of the insert.
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 – 552
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 – 553

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ISUZU KB P190 2007

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 6A1–314
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 6A1–318
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 6A1–320
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 6A1–332
Page 6A1–332
Engine Block Front

Figure 6A1 – 614
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
2 M10 x 1.5 211 212 213 214 215 33.5 27.0
3 M8 x 1.25 207 207 208 209 210 Thru 23.0
4 M8 x 1.25 207 207 208 209 210 Thru Thru
5 M10 x 1.5 212 212 213 214 215 28.0 28.0
6 M10 x 1.5 212 212 213 214 215 Thru 20.0
7 M10 x 1.5 212 212 213 214 215 Thru 28.8

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ISUZU KB P190 2007