Main Cap Bolt Hole Thread Repair

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

1. The main cap bolt hole thread repair kit consists of the following items:
   Fig 1: Identifying Drill, Fixture Plate, Long And Short Bolts, Alignment Pin And Bushing

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   • Drill (1)
   • Tap (2)
   • Installer (3)
   • Fixture Plate (4)
   • Long Bolts (5)
   • Short Bolts (6)
   • Alignment Pin (7)
   • Bushing (8)
2. Remove the alignment dowel pins from the holes (1-4), if necessary.
   Fig 2: Identifying Dowel Pins Holes

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3. Install the fixture plate (1), bolt, and bushing, onto the engine block.

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

   Fig 3: Identifying Fixture Plate

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4. Position the alignment pin in the desired hole and tighten the fixture retaining bolts.
5. Drill out the damaged hole.
6. Refer to SAFETY GLASSES AND COMPRESSED AIR WARNING .

   Using compressed air, clean out any chips.

7. 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 aligns with the top of the bushing (2).

   Fig 4: Identifying Fixture Plate And Bushing

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8. Refer to SAFETY GLASSES AND COMPRESSED AIR WARNING .

   Refer to CLEANING SOLVENT WARNING .

   Using compressed air, clean out any chips.

9. Spray cleaner into the hole. Refer to ADHESIVES, FLUIDS, LUBRICANTS, AND SEALERS (LDK, LHU) .
10. Using compressed air, clean any cutting oil and chips out of the hole.
11. 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 5: Lubricating Threads Of Installer Tool Using Driver Oil

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12. Install the insert (2) onto the driver tool (1).
    Fig 6: Installing Insert Onto Driver Tool

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13. Apply threadlock LOCTITE™ 277, EN-43600-109 (1), or equivalent to the insert OD threads (2).
    Fig 7: Applying Threadlock LOCTITE 277 To Insert OD Threads

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14. NOTE: The fixture plate and bushing remains installed onto the engine block during the insert installation procedure.

    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.

    Fig 8: Identifying Fixture Plate And Bushing

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15. Remove the driver, bushing (2), fixture plate (1), and bolts.
16. Install the alignment dowel pins in holes (1-4), if necessary.
    Fig 9: Identifying Dowel Pins Holes

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