11 00 610 Repairing threads on magnesium engine block

IMPORTANT: Any work on the magnesium that creates dust must not be carried out without suitable dust extraction apparatus in place.

Magnesium and water can react by forming magnesium hydroxide and hydrogen.

Do not use any emulsions containing water to lubricate the magnesium material.

Only engine oil may be used for lubrication.

IMPORTANT: Aluminium-magnesium materials.

No steel screws/bolts may be used due to the threat of electrochemical corrosion.

A magnesium crankcase requires aluminium screws/bolts exclusively.

Aluminium screws/bolts must be replaced each time they are released.

The end faces of aluminium screws/bolts are painted blue for the purposes of reliable identification.

Jointing torque and angle of rotation must be observed without fail (risk of damage).

Tape off parts to be cleaned (3) cleanly and protect against chips.

Use core drill bit (2) with hand drill (1).

Installation:

Ensure exact angularity to workpiece.

Blow out core bore cleanly.

No chips are permitted in the drilled hole.

Fig 1: Identifying Core Drill Bit, Hand Drill And Clean Area

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Screw in Helicoil drill bit (2) with die (1).

Installation:

Ensure exact angularity to workpiece.

Fig 2: Identifying Helicoil Drill Bit And Die

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IMPORTANT: Do not allow chips (1) to come into contact with water.

Danger of fire and explosion.

Fig 3: Identifying Magnesium Chips

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Screw in aluminium Helicoil (1) by hand in direction of arrow as far as it will go.

Adjust spacer (2) approx. 1 mm.

Secure spacer (2) with lock nut (3).

Fig 4: Identifying Spacer, Lock Nut, Helicoil-Plus And Helicoil

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Screw in Helicoil-Plus (1) with preassembled aluminium Helicoil.

Fig 5: Identifying Helicoil-Plus

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Screw aluminium Helicoil into workpiece (1) as far as it will go.

Remove Helicoil-Plus (2) again after screwing in.

Installation:

Aluminium Helicoil remains in workpiece (1).

Fig 6: Identifying Helicoil-Plus And Workpiece

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Break mounting hook off with mounting mandrel (1).

NOTE: Blow mounting hook out of pocket hole with compressed air.

Fig 7: Identifying Mounting Mandrel

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Assemble engine.