Page 3081 of 6020

Engine Mechanical – V6 Page 6A1–304
Page 6A1–304
3 If the threaded hole being repaired has a base
surface perpendicular to t he 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 – 554
General Thread Repair
NOTE
The use of a cutting type fluid such as WD 40® or
equivalent is recommended when performing the
drilling, counter bori ng and tapping procedures
1 When installed to the corre ct depth, the flange (1) of
the insert will be seated agai nst the counter bore of
the drilled/tapped hole and just below the surface (2)
of the base material.
Figure 6A1 – 555
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 – 556
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ISUZU KB P190 2007
Page 3082 of 6020
Engine Mechanical – V6 Page 6A1–305
Page 6A1–305
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 – 557
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 – 558
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 – 559
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ISUZU KB P190 2007
Page 3083 of 6020
Engine Mechanical – V6 Page 6A1–306
Page 6A1–306
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.
6 Using a suitable tapping wr ench, 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 – 560
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 – 561
8 Spray a commercially available thread cleaner into the tapped hole.
Figure 6A1 – 562
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ISUZU KB P190 2007
Page 3084 of 6020
Engine Mechanical – V6 Page 6A1–307
Page 6A1–307
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 – 563
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 – 564
11 Install the insert (2) onto t he driver installation tool (1).
Figure 6A1 – 565
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ISUZU KB P190 2007
Page 3085 of 6020
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
Page 3086 of 6020

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
Page 3087 of 6020

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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Page 3088 of 6020
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