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Thread Repair Specifications

WARNING: This page is about a different car, the 2007 Suzuki XL7. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Identifying Left Cylinder Head Camshaft Cover Face
G04842388Courtesy of SUZUKI OF AMERICA CORP.
LEFT CYLINDER HEAD CAMSHAFT COVER FACE SPECIFICATION

Hole Location Thread Size Drill Counter Bore Tool Stop Collar Tap Driver Insert Drill Depth (Maximum) Tap Depth (Minimum)
- - J 42385- MM (IN) MM (IN)
1 M6 x 1.0 201 202 N/A 203 204 205 22.5 0.8858 18.0 0.7087
2 M6 x 1.0 201 202 N/A 203 204 205 THRU THRU
3 M6 x 1.0 701 N/A N/A 203 204 205 28.5 1.1220 24.0 0.9449
4 M20 x 1.5 715 716 N/A 717 718 719 25.0 0.9842 17.0 0.6693
Fig 2: Identifying Left Cylinder Head Front Face
G04842389Courtesy of SUZUKI OF AMERICA CORP.
LEFT CYLINDER HEAD FRONT FACE SPECIFICATION

Hole Location Thread Size Drill Counter Bore Tool Stop Collar Tap Driver Insert Drill Depth (Maximum) Tap Depth (Minimum)
- - J 42385- MM (IN) MM (IN)
1 M8 x 1.25 206 207 N/A 208 209 210 THRU THRU
2 M12 x 1.75 856 857 N/A 858 859 416 40.0 1.5748 32.5 1.2795
3 M8 x 1.25 206 207 N/A 208 209 210 18.0 0.7087 22.5 0.8858
Fig 3: Identifying Left Cylinder Head Intake Face
G04842390Courtesy of SUZUKI OF AMERICA CORP.
LEFT CYLINDER HEAD INTAKE FACE SPECIFICATION

Hole Location Thread Size Drill Counter Bore Tool Stop Collar Tap Driver Insert Drill Depth (Maximum) Tap Depth (Minimum)
- - J 42385- MM (IN) MM (IN)
1 M8 x 1.25 206 207 N/A 208 209 210 28.5 1.1220 23.0 0.9055
Fig 4: Identifying Left Cylinder Head Exhaust Face
G04842391Courtesy of SUZUKI OF AMERICA CORP.
LEFT CYLINDER HEAD EXHAUST FACE SPECIFICATION

Hole Location Thread Size Drill Counter Bore Tool Stop Collar Tap Driver Insert Drill Depth (Maximum) Tap Depth (Minimum)
- - J 42385- MM (IN) MM (IN)
1 M10 x 1.5 211 212 N/A 213 214 215 33.5 1.3189 27.0 1.0630
2 M12 x 1.5 705 706 N/A 707 708 709 27.5 1.0827 13.0 0.5118
3 M6 x 1.0 201 202 N/A 203 204 205 22.5 0.8858 18.0 0.0000
4 M8 x 1.25 206 207 N/A 208 209 210 28.5 1.1220 23.0 0.9055
Fig 5: Identifying Left Cylinder Head Rear Face
G04842392Courtesy of SUZUKI OF AMERICA CORP.
LEFT CYLINDER HEAD REAR FACE SPECIFICATION

Hole Location Thread Size Drill Counter Bore Tool Stop Collar Tap Driver Insert Drill Depth (Maximum) Tap Depth (Minimum)
- - J 42385- MM (IN) MM (IN)
1 M10 x 1.5 211 212 N/A 213 214 215 33.5 1.3189 27.0 1.0630
Fig 6: Identifying Right Cylinder Head Camshaft Cover Face
G04842393Courtesy of SUZUKI OF AMERICA CORP.
RIGHT CYLINDER HEAD CAMSHAFT COVER FACE SPECIFICATION

Hole Location Thread Size Drill Counter Bore Tool Stop Collar Tap Driver Insert Drill Depth (Maximum) Tap Depth (Minimum)
- - J 42385- MM (IN) MM (IN)
1 M6 x 1.0 201 202 N/A 203 204 205 THRU THRU
2 M6 x 1.0 701 N/A N/A 203 204 205 28.5 1.1220 24.0 0.9449
3 M20 x 1.5 715 716 N/A 717 718 719 25.0 0.9842 17.0 0.6693
4 M6 x 1.0 201 202 N/A 203 204 205 22.5 0.8858 18.0 0.7087
Fig 7: Identifying Right Cylinder Head Front Face
G04842394Courtesy of SUZUKI OF AMERICA CORP.
RIGHT CYLINDER HEAD FRONT FACE SPECIFICATION

Hole Location Thread Size Drill Counter Bore Tool Stop Collar Tap Driver Insert Drill Depth (Maximum) Tap Depth (Minimum)
- - J 42385- MM (IN) MM (IN)
1 M8 x 1.25 206 207 N/A 208 209 210 THRU THRU
2 M6 x 1.0 201 202 N/A 203 204 205 22.5 0.8880 18.0 0.7087
3 M6 x 1.0 201 202 N/A 203 204 205 THRU THRU
4 M8 x 1.25 206 207 N/A 208 209 210 28.5 1.1220 23.0 0.9055
5 M12 x 1.75 856 857 N/A 858 859 416 40.0 1.5748 32.5 1.2795
Fig 8: Identifying Right Cylinder Head Intake Face
G04842395Courtesy of SUZUKI OF AMERICA CORP.
RIGHT CYLINDER HEAD INTAKE FACE SPECIFICATION

Hole Location Thread Size Drill Counter Bore Tool Stop Collar Tap Driver Insert Drill Depth (Maximum) Tap Depth (Minimum)
- - J 42385- MM (IN) MM (IN)
1 M8 x 1.25 206 207 N/A 208 209 210 28.5 1.1220 23.0 0.9055
Fig 9: Identifying Right Cylinder Head Exhaust Face
G04842396Courtesy of SUZUKI OF AMERICA CORP.
RIGHT CYLINDER HEAD EXHAUST FACE SPECIFICATION

Hole Location Thread Size Drill Counter Bore Tool Stop Collar Tap Driver Insert Drill Depth (Maximum) Tap Depth (Minimum)
- - J 42385- MM (IN) MM (IN)
1 M6 x 1.0 201 202 N/A 203 204 205 22.5 0.8858 18.0 0.0000
2 M10 x 1.5 211 212 N/A 213 214 215 33.5 1.3189 27.0 1.0630
3 M8 x 1.25 206 207 N/A 208 209 210 28.5 1.1220 23.0 0.9055
Fig 10: Identifying Right Cylinder Head Rear Face
G04842397Courtesy of SUZUKI OF AMERICA CORP.
RIGHT CYLINDER HEAD REAR FACE SPECIFICATION

Hole Location Thread Size Drill Counter Bore Tool Stop Collar Tap Driver Insert Drill Depth (Maximum) Tap Depth (Minimum)
- - J 42385- MM (IN) MM (IN)
1 M10 x 1.5 211 212 N/A 213 214 215 33.5 1.3189 27.0 1.0630
Fig 11: Identifying Engine Block Front
G04842398Courtesy of SUZUKI OF AMERICA CORP.
ENGINE BLOCK FRONT SPECIFICATION

Hole Location Thread Size Drill Counter Bore Tool Stop Collar Tap Driver Insert Drill Depth (Maximum) Tap Depth (Minimum)
- - J 42385- MM (IN) MM (IN)
1 M8 x 1.25 206 207 N/A 208 209 210 28.5 1.1220 23.0 0.9055
2 M10 x 1.5 211 212 N/A 213 214 215 33.5 1.3189 27.0 1.0630
3 M8 x 1.25 206 207 N/A 208 209 210 THRU 23.0 0.9055
4 M8 x 1.25 206 207 N/A 208 209 210 THRU THRU
5 M10 x 1.5 211 212 N/A 213 214 215 28.0 1.1024 28.0 1.1024
6 M10 x 1.5 211 212 N/A 213 214 215 THRU 20.0 0.7874
7 M10 x 1.5 211 212 N/A 213 214 215 THRU 28.0 1.1024
Fig 12: Identifying Engine Block Left Side
G04842399Courtesy of SUZUKI OF AMERICA CORP.
ENGINE BLOCK LEFT SIDE SPECIFICATION

Hole Location Thread Size Drill Counter Bore Tool Stop Collar Tap Driver Insert Drill Depth (Maximum) Tap Depth (Minimum)
- - J 42385- MM (IN) MM (IN)
1 M8 x 1.25 206 207 N/A 208 209 210 28.5 1.1220 23.0 0.9055
2 M20 x 1.5 715 716 N/A 717 718 719 30.0 1.1810 20.0 0.7874
3 M10 x 1.5 211 212 N/A 213 214 215 33.5 1.3190 27.0 1.0630
4 M14 x 1.5 409 410 N/A 411 412 735 THRU 15.0 0.5905
5 M8 x 1.25 206 207 N/A 208 209 415 16.5 0.6496 11.0 0.4331
Fig 13: Identifying Engine Block Right Side
G04842400Courtesy of SUZUKI OF AMERICA CORP.
ENGINE BLOCK RIGHT SIDE SPECIFICATION

Hole Location Thread Size Drill Counter Bore Tool Stop Collar Tap Driver Insert Drill Depth (Maximum) Tap Depth (Minimum)
- - J 42385- MM (IN) MM (IN)
1 M6 x 1.0 201 202 N/A 203 204 205 22.5 0.8858 18.0 0.7087
2 M8 x 1.25 206 207 N/A 208 209 210 28.5 1.1220 23.0 0.9055
3 M14 x 1.5 409 410 N/A 411 412 735 THRU 15.0 0.5905
4 M10 x 1.5 211 212 N/A 213 214 215 33.5 1.3190 27.0 1.0630
Fig 14: Identifying Engine Block Rear
G04842401Courtesy of SUZUKI OF AMERICA CORP.
ENGINE BLOCK REAR SPECIFICATION

Hole Location Thread Size Drill Counter Bore Tool Stop Collar Tap Driver Insert Drill Depth (Maximum) Tap Depth (Minimum)
- - J 42385- MM (IN) MM (IN)
1 M10 x 1.5 211 212 N/A 213 214 420 33.5 1.3190 27.0 1.0630
2 M6 x 1.0 201 202 N/A 203 204 205 22.5 0.8858 18.0 0.7087
3 M14 x 1.5 409 410 N/A 411 412 735 THRU 15.0 0.5905
4 M10 x 1.5 211 212 N/A 213 214 216 39.5 1.5551 33.0 1.2992
5 M10 x 1.5 211 212 N/A 213 214 420 THRU THRU
Fig 15: Identifying Engine Block Bottom
G04842402Courtesy of SUZUKI OF AMERICA CORP.
ENGINE BLOCK BOTTOM SPECIFICATION

Hole Location Thread Size Drill Counter Bore Tool Stop Collar Tap Driver Insert Drill Depth (Maximum) Tap Depth (Minimum)
- - J 42385- MM (IN) MM (IN)
1 M10 x 2.0 720 N/A N/A 721 722 104 56.0 2.2047 49.0 1.9291
2 M8 x 1.25 702 N/A N/A 703 704 620 46.0 1.8110 40.5 1.5945
3 M8 x 1.25 206 207 N/A 208 209 210 28.5 1.1220 23.0 0.9055
4 M6 x 1.0 201 202 N/A 203 204 205 THRU THRU
Fig 16: Identifying Engine Block Left Deck Face
G04842403Courtesy of SUZUKI OF AMERICA CORP.
ENGINE BLOCK LEFT DECK FACE SPECIFICATION

Hole Location Thread Size Drill Counter Bore Tool Stop Collar Tap Driver Insert Drill Depth (Maximum) Tap Depth (Minimum)
- - J 42385- MM (IN) MM (IN)
1 M8 x 1.25 206 207 N/A 208 209 210 28.5 1.1220 23.0 0.9055
2 M11 x 2.0 723 N/A N/A 724 725 108 102.5 4.0354 94.0 3.7008
Fig 17: Identifying Engine Block Right Deck Face
G04842404Courtesy of SUZUKI OF AMERICA CORP.
ENGINE BLOCK RIGHT DECK FACE SPECIFICATION

Hole Location Thread Size Drill Counter Bore Tool Stop Collar Tap Driver Insert Drill Depth (Maximum) Tap Depth (Minimum)
- - J 42385- MM (IN) MM (IN)
1 M11 x 2.0 723 N/A N/A 724 725 108 102.5 4.0354 94.0 3.7008
2 M8 x 1.25 206 207 N/A 208 209 210 28.5 1.1220 23.0 0.9055
Fig 18: Identifying Engine Front Cover
G04842405Courtesy of SUZUKI OF AMERICA CORP.
ENGINE FRONT COVER SPECIFICATION

Hole Location Thread Size Drill Counter Bore Tool Stop Collar Tap Driver Insert Drill Depth (Maximum) Tap Depth (Minimum)
- - J 42385- MM (IN) MM (IN)
1 M6 x 1.0 201 202 N/A 203 204 205 THRU THRU
2 M6 x 1.0 201 202 N/A 203 204 205 21.5 0.8465 18.0 0.7087
3 M8 x 1.25 206 207 N/A 208 209 210 28.5 1.1220 23.0 0.9055
4 M10 x 1.5 211 212 N/A 213 214 420 THRU THRU
5 M10 x 1.5 211 212 N/A 213 214 420 33.5 1.3189 27.0 1.0630
6 M8 x 1.25 206 207 N/A 208 209 210 27.5 1.0827 23.0 0.9055
Fig 19: Identifying Upper Intake Manifold - Top
G04842406Courtesy of SUZUKI OF AMERICA CORP.
UPPER INTAKE MANIFOLD - TOP SPECIFICATION

Hole Location Thread Size Drill Counter Bore Tool Stop Collar Tap Driver Insert Drill Depth (Maximum) Tap Depth (Minimum)
- - J 42385- MM (IN) MM (IN)
1 M6 x 1.0 201 202 N/A 203 204 205 THRU THRU
2 M6 x 1.0 201 202 N/A 203 204 205 22.5 0.8858 18.0 0.7087
Fig 20: Identifying Upper Intake Manifold - Front
G04842407Courtesy of SUZUKI OF AMERICA CORP.
UPPER INTAKE MANIFOLD - FRONT SPECIFICATION

Hole Location Thread Size Drill Counter Bore Tool Stop Collar Tap Driver Insert Drill Depth (Maximum) Tap Depth (Minimum)
- - J 42385- MM (IN) MM (IN)
1 M6 x 1.0 201 202 N/A 203 204 205 THRU THRU
Fig 21: Identifying Lower Intake Manifold - Top
G04842408Courtesy of SUZUKI OF AMERICA CORP.
LOWER INTAKE MANIFOLD - TOP SPECIFICATION

Hole Location Thread Size Drill Counter Bore Tool Stop Collar Tap Driver Insert Drill Depth (Maximum) Tap Depth (Minimum)
- - J 42385- MM (IN) MM (IN)
1 M6 x 1.0 201 202 N/A 203 204 205 THRU THRU
2 M8 x 1.25 206 207 N/A 208 209 210 THRU THRU
Fig 22: Identifying Oil Pan Front
G04842409Courtesy of SUZUKI OF AMERICA CORP.
OIL PAN FRONT SPECIFICATION

Hole Location Thread Size Drill Counter Bore Tool Stop Collar Tap Driver Insert Drill Depth (Maximum) Tap Depth (Minimum)
- - J 42385- MM (IN) MM (IN)
1 M10 x 1.5 211 212 N/A 213 214 420 33.5 1.3189 27.0 1.0630
2 M12 x 1.75 856 857 N/A 858 859 416 39.5 1.5551 32.0 1.2598
3 M8 x 1.25 206 207 N/A 208 209 210 28.5 1.1220 23.0 0.9055
4 M8 x 1.25 610 N/A N/A 208 209 620 37.5 1.4764 32.0 1.2598
Fig 23: Identifying Oil Pan Left Side
G04842410Courtesy of SUZUKI OF AMERICA CORP.
OIL PAN LEFT SIDE SPECIFICATION

Hole Location Thread Size Drill Counter Bore Tool Stop Collar Tap Driver Insert Drill Depth (Maximum) Tap Depth (Minimum)
- - J 42385- MM (IN) MM (IN)
1 M10 x 1.5 211 212 N/A 213 214 420 33.5 1.3189 27.0 1.0630
Fig 24: Identifying Oil Pan Right Side
G04842411Courtesy of SUZUKI OF AMERICA CORP.
OIL PAN RIGHT SIDE SPECIFICATION

Hole Location Thread Size Drill Counter Bore Tool Stop Collar Tap Driver Insert Drill Depth (Maximum) Tap Depth (Minimum)
- - J 42385- MM (IN) MM (IN)
1 M12 x 1.75 856 857 N/A 858 859 416 THRU THRU
2 M8 x 1.25 206 207 N/A 208 209 210 28.5 1.1220 23.0 0.9055
3 M10 x 1.5 211 212 N/A 213 214 420 33.5 1.3189 27.0 1.0630
Fig 25: Identifying Oil Pan Rear
G04842412Courtesy of SUZUKI OF AMERICA CORP.
OIL PAN REAR SPECIFICATION

Hole Location Thread Size Drill Counter Bore Tool Stop Collar Tap Driver Insert Drill Depth (Maximum) Tap Depth (Minimum)
- - J 42385- MM (IN) MM (IN)
1 M10 x 1.5 211 212 N/A 213 214 420 33.5 1.3189 27.0 1.0630
Fig 26: Identifying Oil Pan Top
G04842413Courtesy of SUZUKI OF AMERICA CORP.
OIL PAN TOP SPECIFICATION

Hole Location Thread Size Drill Counter Bore Tool Stop Collar Tap Driver Insert Drill Depth (Maximum) Tap Depth (Minimum)
- - J 42385- MM (IN) MM (IN)
1 M6 x 1.0 701 N/A N/A 203 204 205 28.0 1.1024 23.5 0.9252
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