Tools Required

1. It is critical that the drilling, counterboring and tapping of the hole to be repaired follows the same centerline as the original hole.



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.



3. If the threaded hole being repaired has a base surface perpendicular to the hole centerline, tapping guides are available to aid in tapping the hole.

Important: 

•	During the drilling process, it is necessary to repeatedly remove the drill and clean chips from the hole and the flutes of the drill.

•	DO NOT drill any further than the original hole depth.

1. Drill out the threads of the damaged hole.

Specifications

•	M6 inserts require a minimum drill depth of 15 mm (0.59 in).

•	M8 inserts require a minimum drill depth of 20 mm (0.79 in).

•	M10 inserts require a minimum drill depth of 23.5 mm (0.93 in).





Important: All chips must be removed from the drilled hole prior to tapping.

2. Using compressed air, clean out any chips.




Important: A correctly counterbored hole will show a slight burnishing on the surface of the base material for 360 degrees around the drilled hole.

3. Counterbore the drilled hole to the full depth permitted by the tool (1).




Important: All chips must be removed from the drilled hole prior to tapping.

4. Using compressed air, clean out any chips.




Important: 

•	During the tapping process, it is necessary to repeatedly remove the tap and clean chips from the hole and the flutes of the tap.

•	Make sure the tap has created full threads at least to the depth equal to the insert length.

5. Using a suitable tapping wrench, tap the threads of the drilled hole by hand only.

Specifications

•	M6 inserts require a minimum tap depth of 15 mm (0.59 in).

•	M8 inserts require a minimum tap depth of 20 mm (0.79 in).

•	M10 inserts require a minimum tap depth of 23.5 mm (0.93 in).





Important: All chips must be removed from the tapped hole prior to insert installation.

6. Using compressed air, clean out any chips.



7. Spray a commercially available thread cleaner (2) into the tapped hole (1).




Important: All chips must be removed from the tapped hole prior to insert installation.

8. Using compressed air, clean out any chips.




Important: DO NOT allow oil or other foreign material to contact the Outside Diameter (OD) of the insert.

9. Lubricate the threads of the driver installation tool (2) with the driver oil (1).



10. Install the insert (2) onto the driver installation tool (1).



11. Apply threadlock sealant LOCTITE 277® or equivalent (1) to the insert OD threads (2).



12. Install the insert (1) into the tapped hole by hand only.

Install the insert until the flange of the insert contacts the counterbored surface. Continue to rotate the installer tool (1) through the insert.

The installer tool will tighten up before screwing completely through the insert. This is acceptable. You are forming the bottom threads of the insert and mechanically locking the insert to the base material threads.




13. Inspect the insert for correct installation into the hole.

A correctly installed insert (1) will be either flush or slightly below flush with the surface of the base material (2).




14. 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 chips 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.

1. Install a stop collar (2) on the counterbore drill (1), if required.




Important: 

•	During the drilling process, it is necessary to repeatedly remove the drill and clean chips from the hole and the flutes of the drill.

•	Drill the hole until the stop collar contacts the surface of the base material.

2. Drill out the threads of the damaged hole.




Important: All chips must be removed from the drilled hole prior to tapping.

3. Using compressed air, clean out any chips.




Important: 

•	During the tapping process, it is necessary to repeatedly remove the tap and clean chips from the hole and the flutes of the tap.

•	Make sure the tap has created full threads at least to the depth equal to the insert length.

4. Using a suitable tapping wrench, tap the threads of the drilled hole by hand only.




Important: All chips must be removed from the tapped hole prior to insert installation.

5. Using compressed air, clean out any chips.



6. Spray a commercially available thread cleaner (2) into the tapped hole (1).




Important: All chips must be removed from the tapped hole prior to insert installation.

7. Using compressed air, clean out any chips.




Important: DO NOT allow oil or other foreign material to contact the Outside Diameter (OD) of the insert.

8. Lubricate the threads of the driver installation tool (2) with the driver oil (1).



9. Install the insert (2) onto the driver installation tool (1).



10. Apply threadlock sealant LOCTITE 277® or equivalent (1) to the insert OD threads (2).



11. Install the insert (1) into the tapped hole by hand only.




Important: If the insert will not thread down until the flange contacts the counterbored surface remove the insert immediately with a screw extracting tool and inspect the tapped hole for any remaining chips and/or incorrect tapping.

12. Install the insert until the flange (1) of the insert contacts the counterbored surface.




Important: The driver installation tool will tighten up before screwing 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.

13. Continue to rotate the driver installation tool (1) through the insert (2).



14. Inspect the insert (1) for correct installation (2) into the tapped hole.



15. 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 chips 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.

Important: 

•	The thread repair insert for tapered pipe threads is coated with a clear silver zinc coating.

•	During the drilling process, it is necessary to repeatedly remove the drill and clean chips from the hole and the flutes of the drill.

•	Drill the hole until the stop collar contacts the surface of the base material.

1. Drill out the threads of the damaged hole.




Important: All chips must be removed from the drilled hole prior to tapping.

2. Using compressed air, clean out any chips.




Important: 

•	During the tapping process, it is necessary to repeatedly remove the tap and clean chips from the hole and the flutes of the tap.

•	Make sure the tap has created full threads at least to the depth equal to the insert length.

3. Using a suitable tapping wrench, tap the threads of the drilled hole by hand only.



4. Tap the drilled hole until the threads at the top of the tap (1) are down to the surface of the base material (2).




Important: All chips must be removed from the tapped hole prior to insert installation.

5. Using compressed air, clean out any chips.



6. Spray a commercially available thread cleaner (2) into the tapped hole (1).




Important: All chips must be removed from the tapped hole prior to insert installation.

7. Using compressed air, clean out any chips.




Important: DO NOT allow oil or other foreign material to contact the Outside Diameter (OD) of the insert.

8. Lubricate the threads of the driver installation tool (2) with the driver oil (1).



9. Install the insert (2) onto the driver installation tool (1).



10. Apply threadlock sealant LOCTITE 277® or equivalent (1) to the insert OD threads (2).



11. Install the insert (1) into the tapped hole by hand only.




Important: If the insert will not thread down until the flange contacts the surface of the base material remove the insert immediately with a screw extracting tool and inspect the tapped hole for any remaining chips and/or incorrect tapping.

12. Install the insert until the flange (1) of the insert contacts the surface of the base material.




Important: The driver installation tool will tighten up before screwing 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.

13. Continue to rotate the driver installation tool (1) until the top of the threaded section (2) is level with the top of the insert (3).



14. Inspect the insert (1) for correct installation (2) into the tapped hole.



15. 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 chips 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.

Tools Required

•	The cylinder head bolt hole thread repair tooling are in the kits J 42385-2000 and J 42385-700 . The cylinder head bolt hole thread repair components consist of the following:

Caution: Refer to Safety Glasses Caution in the Preface section.

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.



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 (1) from the cylinder head bolt hole.




Important: 

•	During the drilling process, it is necessary to repeatedly remove the drill and clean chips from the hole and the flutes of the drill.

•	Drill the hole until the stop collar contacts the top of the drill bushing.

6. Drill out the threads of the damaged hole.




Important: All chips must be removed from the drilled hole prior to tapping.

7. Using compressed air, clean out any chips.




Important: 

•	During the tapping process, it is necessary to repeatedly remove the tap and clean chips from the hole and the flutes of the tap.

•	Make sure the tap has created full threads at least to the depth equal to the insert length.

8. Using a suitable tapping wrench (1), tap the threads of the drilled hole by hand only.



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.




Important: Remove the fixture plate prior to installing the insert with the installer tool.

10. Remove the fixture plate bolts (2).
11. Remove the fixture plate (3) and bushing (1).




Important: All chips must be removed from the tapped hole prior to insert installation.

12. Using compressed air, clean out any chips.



13. Spray a commercially available thread cleaner (2) into the tapped hole (1).




Important: All chips must be removed from the tapped hole prior to insert installation.

14. Using compressed air, clean out any chips.




Important: DO NOT allow oil or other foreign material to contact the outside diameter (OD) of the insert.

15. Lubricate the threads of the driver installation tool (2) with the driver oil (1).



16. Install the insert (2) onto the driver installation tool (1).



17. Apply threadlock sealant such as LOCTITE 277®; or equivalent (1) to the insert OD threads (2).



18. Install the insert and installation driver (1) into the tapped hole by hand only.
19. Start the insert into the threaded hole.

Important: If the insert will not thread down until the flange contacts the counterbored surface remove the insert immediately with a screw extracting tool and inspect the tapped hole for any remaining chips and/or incorrect tapping.

20. Install the insert until the flange of the insert contacts the counterbored surface.

Important: The driver installation tool will tighten up before screwing 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.

21. Continue to rotate the driver installation tool through the insert.



22. In order to completely form the new threads in the insert, rotate the driver installation tool through the insert until the mark (1) on the driver installation tool aligns with the surface of the cylinder block deck (2).
23. Inspect the insert for correct installation into the tapped hole.

Tools Required

•

Important:     •  In order to repair some crankshaft main bolt holes it will be necessary to mount the fixture plate upside down.    •  DO NOT remove the fixture plate prior to installing the insert with the installation driver. The fixture plate remains in position throughout the thread repair process. The crankshaft main bearing bolt hole thread repair tooling are in the kits J 42385-2000 and J 42385-700 . The crankshaft main bearing bolt hole thread repair components consist of the following:

Caution: Refer to Safety Glasses Caution in the Preface section.

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.



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 fixture retaining bolts (2).
5. Remove the alignment pin (1) from the crankshaft main cap bolt hole.




Important: 

•	During the drilling process, it is necessary to repeatedly remove the drill and clean chips from the hole and the flutes of the drill.

•	Drill the crankshaft main bolt hole until the mark (1) on the drill aligns with the top of the drill bushing (2).

6. Drill out the threads of the damaged hole.




Important: All chips must be removed from the drilled hole prior to tapping.

7. Using compressed air, clean out any chips.




Important: 

•	DO NOT remove the fixture plate, ensure the fixture plate is installed during the machining and installation processes of the insert.

•	During the tapping process, it is necessary to repeatedly remove the tap and clean chips from the hole and the flutes of the tap.

•	Make sure the tap has created full threads at least to the depth equal to the insert length.

8. Using a suitable tapping wrench (1), tap the threads of the drilled hole by hand only.



9. In order to tap the new threads for the insert to the correct depth, rotate the tap into the crankshaft main cap bolt hole until the mark (1) on the tap aligns with the top of the drill bushing (2).




Important: All chips must be removed from the tapped hole prior to insert installation.

10. Using compressed air, clean out any chips.



11. Spray a commercially available thread cleaner (2) into the tapped hole (1).




Important: All chips must be removed from the tapped hole prior to insert installation.

12. Using compressed air, clean out any chips.




Important: 

•	DO NOT remove the fixture plate, make sure the fixture plate is installed during the installation process of the insert.

•	DO NOT allow oil or other foreign material to contact the Outside Diameter (OD) of the insert.

13. Lubricate the threads of the driver installation tool (2) with the driver oil (1).



14. Install the insert (2) onto the driver installation tool (1).



15. Apply threadlock sealant such as LOCTITE 277®, or equivalent (1) to the insert OD threads (2).



16. Install the insert and installation driver (1) into the tapped hole by hand only.
17. Start the insert into the threaded hole.

Important: If the insert will not thread down until the flange contacts the counterbored surface remove the insert immediately with a screw extracting tool and inspect the tapped hole for any remaining chips and/or incorrect tapping.

18. Install the insert until the flange of the insert contacts the counterbored surface.

Important: The driver installation tool (1) will tighten up before screwing 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 (1) through the insert.



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.



22. Remove the fixture plate bolts (1).
23. Remove the fixture plate (3) and bushing (2).

Caution: Refer to Safety Glasses Caution in the Preface section.

1. Position the fixture plate (3) with the bushing (1) installed over the crankshaft main cap bolt hole to be repaired.
2. Loosely install the fixture plate bolts (2) into the remaining crankshaft main cap bolt holes.



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 fixture retaining bolts (2).
5. Remove the alignment pin (1) from the crankshaft main cap bolt hole.




Important: 

•	During the drilling process, it is necessary to repeatedly remove the drill and clean chips from the hole and the flutes of the drill.

•	Drill the crankshaft main bolt hole until the mark (1) on the drill aligns with the top of the drill bushing (2).

6. Drill out the threads of the damaged hole.




Important: All chips must be removed from the drilled hole prior to tapping.

7. Using compressed air, clean out any chips.




Important: 

•	DO NOT remove the fixture plate, ensure the fixture plate is installed during the machining and installation processes of the insert.

•	During the tapping process, it is necessary to repeatedly remove the tap and clean chips from the hole and the flutes of the tap.

•	Make sure the tap has created full threads at least to the depth equal to the insert length.

8. Using a suitable tapping wrench, tap the threads of the drilled hole by hand only.



9. In order to tap the new threads for the insert to the correct depth, rotate the tap into the crankshaft main cap bolt hole until the mark (1) on the tap aligns with the top of the drill bushing (2).




Important: All chips must be removed from the tapped hole prior to insert installation.

10. Using compressed air, clean out any chips.



11. Spray a commercially available thread cleaner (2) into the tapped hole (1).




Important: All chips must be removed from the tapped hole prior to insert installation.

12. Using compressed air, clean out any chips.




Important: 

•	DO NOTremove the fixture plate, make sure the fixture plate is installed during the installation process of the insert.

•	DO NOT allow oil or other foreign material to contact the Outside Diameter (OD) of the insert.

13. Lubricate the threads of the driver installation tool (2) with the driver oil (1).



14. Install the insert (2) onto the driver installation tool (1).



15. Apply threadlock sealant such as LOCTITE 277®, or equivalent (1) to the insert OD threads (2).



16. Install the insert and installation driver into the tapped hole by hand only.
17. Start the insert into the threaded hole.

Important: If the insert will not thread down until the flange contacts the counterbored surface remove the insert immediately with a screw extracting tool and inspect the tapped hole for any remaining chips and/or incorrect tapping.

18. Install the insert until the flange of the insert contacts the counterbored surface.

Important: The driver installation tool will tighten up before screwing 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.



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.



22. Remove the fixture plate bolts (2).
23. Remove the fixture plate (3) and bushing (1).