LEMON Manuals: Even more car manuals for everyone
Home >> Saturn >> 2002 >> LW200 Automatic >> Repair and Diagnosis >> External Pages >> Different car >> Section 295 (Engine Mechanical) >> Repair Instructions >> Off Vehicle Repair Instructions >> Thread Repair - Main Cap Bolt Hole >> Main Cap Bolt Hole Thread

Main Cap Bolt Hole Thread

WARNING: This page is about a different car, the 2003 Saturn LW200 and 2003 Saturn L200. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View of Main Cap Bolt Thread Repair Kit
    GM898720Courtesy of GENERAL MOTORS CORP.
  1. The main cap bolt thread repair kit consists of the following items:
    • Drill (1)
    • Tap (2)
    • Installer (3)
    • Fixture Plate (4)
    • Long Bolts (5)
    • Short Bolts (6)
    • Alignment Pin (7)
    • Bushing (8)
    2. Fig 2: Identifying Alignment Doll Pins
    GM898749Courtesy of GENERAL MOTORS CORP.
  2. Remove the alignment doll pins on holes 1-4 if necessary.
    3. Fig 3: Installing Fixture Plate
    GM898745Courtesy of GENERAL MOTORS CORP.
  3. Install fixture plate, bolt and bushing onto engine block.

    Position the fixture plate and bushing over the hole that is to be replaced.

  4. Position alignment pin in desired hole and tighten fixture retaining bolts.
  5. Drill out the damaged hole.
  6. Using compressed air, clean out any chips.
    7. Fig 4: Tapping Threads of Drilled Hole
    GM898743Courtesy of GENERAL MOTORS CORP.
  7. Using a tap wrench, tap the threads of the drilled hole.

    In order to tap new threads to the proper depth, rotate the tap into the hole until the mark (3) on the tap aligns with the top of the bushing.

  8. Using compressed air, clean out any chips.
  9. Spray cleaner GM P/N 12346139 (or equivalent) into the hole.
  10. Using compressed air, clean any cutting oil and chips out of the hole.
    11. Fig 5: Applying Lubricant to Thread of Installer Tool
    GM898727Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Do not allow oil or other foreign material to contact the outside diameter (OD) of the insert.
  11. Lubricate the threads of the installer tool (2) with the driver oil (1).
    12. Fig 6: Installing Insert to Driver Tool
    GM898737Courtesy of GENERAL MOTORS CORP.
  12. Install the insert (2) onto the driver tool (1).
    13. Fig 7: Applying Threadlock To Insert
    GM313572Courtesy of GENERAL MOTORS CORP.
  13. Apply High Strength Threadlocker® Red, J42385-109, (or equivalent) to the insert OD threads.
    14. Fig 8: Identifying Bushing, Fixture Plate, & Tool
    GM898743Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The fixture plate and bushing remains installed onto the engine block during the insert installation procedure.
  14. Install the insert and driver through the bushing (2), fixture plate (1) and into the hole.

    Rotate the driver tool until the mark on the tool (3) aligns with the top of the bushing (2).

    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.

  15. Remove the driver, bushing (2), fixture plate (1) and bolts.
    16. Fig 9: Installing Alignment Doll Pins
    GM898749Courtesy of GENERAL MOTORS CORP.
  16. Install the alignment doll pins in holes 1-4 if necessary.
scientia non olet · About LEMON Manuals