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Home >> Saturn >> 2004 >> Ion Red Line >> Repair and Diagnosis >> External Pages >> Different car >> Section 7 (Engine Mechanical) >> Repair Instructions >> Off-Vehicle Repair Instructions >> Thread Repair >> Main Cap Bolt Hole Thread Repair
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Main Cap Bolt Hole Thread Repair

WARNING: This page is about a different car, the 2004 Saturn Ion 3, 2004 Saturn Ion 2, and 2004 Saturn Ion 1. However, it is still accessible from the selected car via links, so may be relevant.
  1. The main cap bolt hole 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 1: Identifying Thread Repair Kit Components
    GM313556Courtesy of GENERAL MOTORS CORP.
  2. Remove the alignment doll pins on the holes (1-4), if necessary.
    3. Fig 2: Identifying Alignment Dowel Pins
    GM747194Courtesy of GENERAL MOTORS CORP.
  3. Install the fixture plate, bolt, and bushing, onto the engine block.

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

    4. Fig 3: Installing Fixture Plate To Engine Block
    GM747192Courtesy of GENERAL MOTORS CORP.
  4. Position the alignment pin in the desired hole and tighten the fixture retaining bolts.
  5. Drill out the damaged hole.
  6. 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).

    8. Fig 4: View Of Fixture Plate, Drill Bushing & Tool Marking
    GM377635Courtesy of GENERAL MOTORS CORP.
  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. 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 5: Lubricating Installer Tool Using Driver Oil
    GM313562Courtesy of GENERAL MOTORS CORP.
  12. Install the insert (2) onto the driver tool (1).
    13. Fig 6: View of Bushing Type Insert
    GM313567Courtesy of GENERAL MOTORS CORP.
  13. Apply threadlock LOCTITE™ 277, J 42385-109 (1), or equivalent to the insert OD threads (2).
    14. Fig 7: Applying Threadlock To Insert
    GM313572Courtesy 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 8: View Of Fixture Plate, Drill Bushing & Tool Marking
    GM377635Courtesy of GENERAL MOTORS CORP.
  16. Install the alignment doll pins in holes (1-4), if necessary.
    17. Fig 9: Identifying Alignment Dowel Pins
    GM747194Courtesy of GENERAL MOTORS CORP.
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