Isuzu KB P190. Service manual — part 771

Engine Mechanical – V6

Page 6A1–307

Page 6A1–307

N O T E

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

N O T E

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 the driver installation tool (1).

Figure 6A1 – 565

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 the flange (2) of the insert
contacts the counter bore surface.

Figure 6A1 – 568

Engine Mechanical – V6

Page 6A1–309

Page 6A1–309

N O T E

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 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 – 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 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 – 571

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

N O T E

• 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 seated 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