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Home >> Saab >> 2011 >> 9-5 Turbo4, Standard >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 1 (Basic Engine, V6) >> Adjustment Replacement >> Thread Repair >> Inboard Bolt Holes
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Inboard Bolt Holes

WARNING: This page is about a different variant/trim than selected.
  1. Refer to SAFETY GLASSES WARNING .
    NOTE:
    • Ensure the fixture plate is installed during the machining and installation processes of the insert.
    • The use of a cutting type fluid, WD 40® or equivalent is recommended when performing the drilling, counterboring and tapping procedures. Refer to ADHESIVES, FLUIDS, LUBRICANTS, AND SEALERS  for recommended cutting fluid.

    When installed to the proper depth, the flange of the insert will be seated against the counterbore of the drilled/tapped hole.

    Position the fixture plate (3) with the bushing (1) installed over the crankshaft main cap bolt hole to be repaired.

    Fig 1: Identifying Fixture Plate, Bushing And Bolts
    G09439040Courtesy of SAAB-SCANIA OF AMERICA, INC.
  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.
    Fig 2: Installing Fixture Plate Bolts Into Crankshaft Main Cap Bolt Holes
    G09439041Courtesy of SAAB-SCANIA OF AMERICA, INC.
  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.
  6. NOTE:
    • 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).

    Drill out the threads of the damaged hole.

    Fig 3: Drilling Out Threads Of Damaged Hole
    G09439042Courtesy of SAAB-SCANIA OF AMERICA, INC.
  7. NOTE: All chips must be removed from the drilled hole prior to tapping.

    Using compressed air, clean out any chips.

    Fig 4: Removing Tapped Hole Chips Using Compressed Air
    G09439043Courtesy of SAAB-SCANIA OF AMERICA, INC.
  8. NOTE:
    • 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.
    • Ensure the tap has created full threads at least to the depth equal to the insert length.

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

    Fig 5: Tapping Threads Of Drilled Hole Using Tapping Wrench
    G09439044Courtesy of SAAB-SCANIA OF AMERICA, INC.
  9. In order to tap the new threads for the insert to the proper depth, rotate the tap into the crankshaft main cap bolt hole until the mark (3) on the tap aligns with the top of the drill bushing (2).
    Fig 6: Aligning Tap Mark With Drill Bushing Top
    G09439045Courtesy of SAAB-SCANIA OF AMERICA, INC.
  10. NOTE: All chips must be removed from the tapped hole prior to insert installation.

    Using compressed air, clean out any chips.

    Fig 7: Removing Tapped Hole Chips Using Compressed Air
    G09439046Courtesy of SAAB-SCANIA OF AMERICA, INC.
  11. Spray cleaner into the tapped hole. Refer to ADHESIVES, FLUIDS, LUBRICANTS, AND SEALERS  for recommended cleaner.
    Fig 8: Spraying Cleaner Into Tapped Hole
    G09439047Courtesy of SAAB-SCANIA OF AMERICA, INC.
  12. NOTE: All chips must be removed from the tapped hole prior to insert installation.

    Using compressed air, clean out any chips.

    Fig 9: Removing Tapped Hole Chips Using Compressed Air
    G09439048Courtesy of SAAB-SCANIA OF AMERICA, INC.
  13. NOTE:
    • Do not remove the fixture plate, ensure 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.

    Lubricate the threads of the driver installation tool (2) with the EN 42385-110 (1).

    Fig 10: Lubricating Driver Installation Tool Threads Using Tool
    G09439049Courtesy of SAAB-SCANIA OF AMERICA, INC.
  14. Install the insert (2) onto the driver installation tool (1).
    Fig 11: Installing Insert Onto Driver Installation Tool
    G09439050Courtesy of SAAB-SCANIA OF AMERICA, INC.
  15. Apply threadlock sealant, EN 42385-109, LOCTITE 277®, or equivalent (1) to the insert OD threads (2). Refer to ADHESIVES, FLUIDS, LUBRICANTS, AND SEALERS  for the recommended sealant.
    Fig 12: Applying Threadlock Sealant To Insert OD Threads
    G09439051Courtesy of SAAB-SCANIA OF AMERICA, INC.
  16. Install the insert and installation driver into the tapped hole by hand only.
    Fig 13: Installing Insert And Installation Driver Into Tapped Hole
    G09439052Courtesy of SAAB-SCANIA OF AMERICA, INC.
  17. Start the insert into the threaded hole.
  18. NOTE: 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 improper tapping.

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

  19. NOTE: 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.

    Continue to rotate the driver installation tool through the insert.

  20. Rotate the driver installation tool until the mark (3) on the driver installation tool aligns with the top of the drill bushing (2).
    Fig 14: Inserting Mechanically Locking Insert Into Base Material Threads
    G09439053Courtesy of SAAB-SCANIA OF AMERICA, INC.
  21. Inspect the insert for proper installation into the tapped hole.
  22. Remove the fixture plate bolts (2).
    Fig 15: Identifying Fixture Plate, Bushing And Bolts
    G09439054Courtesy of SAAB-SCANIA OF AMERICA, INC.
  23. Remove the fixture plate (3) and bushing (1).
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