Cylinder Head Bolt Hole Thread Repair

Refer to ADHESIVES, FLUIDS, LUBRICANTS, AND SEALERS (LDK, LHU)  for recommended cutting fluid and driver oil.

1. The cylinder head bolt hole thread repair kit consists of the following items:
   Fig 1: Identifying Drill, Tap, Sleeve, Bushing, Fixture Plate And Bolts

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   • Drill (1)
   • Tap (2)
   • Installer (3)
   • Sleeve (4)
   • Alignment Pin (5)
   • Bushing (6)
   • Bolts (7)
   • Fixture Plate (8)
2. Refer to SAFETY GLASSES AND COMPRESSED AIR WARNING .

   Install the fixture plate (3), bolts (1), and bushing (2) onto the engine block deck.

   Position the fixture plate and bushing over the hole that is to be repaired (4).

   Fig 2: Installing Fixture Plate, Bolts And Bushing Onto Engine Block Deck

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3. Position the alignment pin (1) through the bushing and into the hole.
   Fig 3: Positioning Alignment Pin

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4. With the alignment pin in the desired hole, tighten the fixture retaining bolts (2).
5. Remove the alignment pin from the hole.
6. Install the sleeve (2) onto the drill (1), if required.
   Fig 4: Installing Sleeve Onto Drill

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7. NOTE: During the reaming process, it is necessary to repeatedly remove the drill and clean the chips from the hole.

   Drill out the threads of the damaged hole.

   Drill the hole until the stop collar (1) of the drill bit or the sleeve contacts the bushing.

   Fig 5: Drilling Out Threads Of Damaged Hole

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8. Refer to SAFETY GLASSES AND COMPRESSED AIR WARNING .

   Using compressed air, clean out any chips.

9. Using a tap wrench (1), tap the threads of the drilled hole.
   Fig 6: Tapping Threads Of Drilled Hole Using Tap Wrench

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10. Using a TAP wrench, tap the threads of the drilled hole.

    In order to tap the new threads to the proper depth, rotate the tap into the hole until the mark (3) on the tap align with the top of the drill bushing (2).

    Fig 7: Identifying Fixture Plate And Bushing

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11. Remove the fixture plate (1), bushing (2), and bolts.
12. Refer to SAFETY GLASSES AND COMPRESSED AIR WARNING . Refer to CLEANING SOLVENT WARNING .

    Using compressed air, clean out any chips.

13. Spray cleaner into the hole. Refer to ADHESIVES, FLUIDS, LUBRICANTS, AND SEALERS (LDK, LHU) .
14. Using compressed air, clean any cutting oil and chips out of the hole.
15. NOTE: Do not allow oil or other foreign material to contact the outside diameter (OD) of the insert.

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

    Fig 8: Lubricating Threads Of Installer Tool Using Driver Oil

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16. Install the insert (2) onto the driver tool (1).
    Fig 9: Installing Insert Onto Driver Tool

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17. Apply threadlock LOCTITE™ 277, EN-43600-109  loctite (1), or equivalent to the insert's OD threads (2).
    Fig 10: Applying Threadlock LOCTITE 277 To Insert OD Threads

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18. Install the insert and driver (1) into the hole.

    Rotate the driver tool until the mark on the tool aligns with the deck surface of the engine block.

    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.

    Fig 11: Installing Driver Into Hole

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