Safety Warning

DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.

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HOMESERVICE MANUALSOLDSMOBILE2004BRAVADA AWDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1207 (ENGINE MECHANICAL - 5.7L)REPAIR INSTRUCTIONSOFF-VEHICLE REPAIR INSTRUCTIONSTHREAD REPAIRCYLINDER HEAD BOLT HOLE THREAD REPAIR

2004 Oldsmobile Bravada AWD

Cylinder Head Bolt Hole Thread Repair

2004 Oldsmobile Bravada AWDSECTION Cylinder Head Bolt Hole Thread Repair

WARNING: This page is about a different car, the 2003 Chevrolet Corvette. However, it is still accessible from the selected car via links, so may be relevant.

The cylinder head bolt hole thread repair kit consists of the following items:
- The drill (1)
- The tap (2)
- The installer (3)
- The sleeve (4)
- The alignment pin (5)
- The bushing (6)
- The bolts (7)
- The fixture plate (8)
  
  Fig 1: Identifying Cylinder Head Bolt Hole Thread Repair Kit Components
  Courtesy of GENERAL MOTORS CORP.
CAUTION: Refer to SAFETY GLASSES CAUTION .

Important: The use of a cutting type fluid GM P/N 1052864 (Canadian P/N 992881), WD 40®, or equivalent is recommended when performing the drilling and tapping procedures.

Driver oil MUST be used on the installer driver tool.

The tool kits are designed for use with either a suitable tap wrench or drill motor.
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
Courtesy of GENERAL MOTORS CORP.
Position the alignment pin (1) through the bushing and into the hole.

Fig 3: Positioning Alignment Pin
Courtesy of GENERAL MOTORS CORP.
With the alignment pin in the desired hole, tighten the fixture retaining bolts (2).
Remove the alignment pin from the hole.
Cylinder head bolt holes 1-8 are the deep holes and will be drilled without the drill sleeve.
Cylinder head bolt holes 9 and 10 are the shallower holes, drilling MUST be done with the drill sleeve in place.

Fig 4: Identifying Cylinder Head Bolt Holes
Courtesy of GENERAL MOTORS CORP.
Install the sleeve (2) onto the drill (1), if required.

Fig 5: Installing Sleeve Onto Drill
Courtesy of GENERAL MOTORS CORP.

Important: 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 of the drill bit or the sleeve contacts the bushing.

Fig 6: Drilling Out Threads Of Damaged Hole
Courtesy of GENERAL MOTORS CORP.
Using compressed air, clean out any chips.
Using a tap wrench, tap the threads of the drilled hole.

Fig 7: Tapping Threads Of Drilled Hole
Courtesy of GENERAL MOTORS CORP.
In order to tap the new threads to the proper depth, rotate the tap into the hole until the marks (1 or 4) on the tap align with the top of the drill bushing (3).
For the deeper cylinder head bolt holes (1-8), rotate the tap until the upper mark on the tap (4) aligns with the top of the drill bushing. For the shallower cylinder head bolt holes (9 and 10), rotate the tap until the lower mark on the tap (1) aligns with the top of the drill bushing.

Fig 8: Locating Drill Depth Marks
Courtesy of GENERAL MOTORS CORP.
Remove the fixture plate (2), bushing (3), and bolts.
Using compressed air, clean out any chips.
Spray cleaner GM P/N 12346139 (Canadian P/N 10953463), GM P/N 12377981 (Canadian P/N 10953463) or equivalent into the hole.
Using compressed air, clean any cutting oil and chips out of the hole.
Important: 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 9: Lubricating Threads Of Installer Tool
Courtesy of GENERAL MOTORS CORP.
Install the insert (2) onto the driver tool (1).

Fig 10: Installing Insert Onto Driver Tool
Courtesy of GENERAL MOTORS CORP.
Apply threadlock LOCTITE™ 277, J 42385-109 (1), or equivalent to the insert OD threads (2).

Fig 11: Applying Threadlock To Insert OD Threads
Courtesy of GENERAL MOTORS CORP.
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 12: Installing Insert And Driver Into Hole
Courtesy of GENERAL MOTORS CORP.