Outboard Bolt Holes

Important: 

• Remove the fixture plate prior to installing the insert with the installer tool.
• The use of a cutting type fluid GM P/N US 1052864, Canada 992881, WD 40® or equivalent is recommended when performing the drilling, counterboring and tapping procedures.

When installed to the proper depth, the flange of the insert will be seated against the counterbore of the drilled/tapped hole.

1. Position the fixture plate (3) with the bushing (2) installed over the cylinder head bolt hole to be repaired (4).
2. Loosely install the fixture plate bolts (1) into the remaining cylinder head bolt holes.
   Fig 1: Installing Fixture Plate Bolts Loosely

   Courtesy of GENERAL MOTORS CORP.
3. Position the alignment pin (1) through the bushing and into the cylinder head bolt hole.
4. With the alignment pin in the desired cylinder head bolt hole, tighten the fixture retaining bolts (2).
5. Remove the alignment pin (1) from the cylinder head bolt hole.
   Fig 2: Removing Alignment Pin

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   Important: 

   • During the drilling process, it is necessary to repeatedly remove the drill and clean chips from the hole and the flutes of the drill.
   • Drill the hole until the stop collar contacts the top of the drill bushing.
6. Drill out the threads of the damaged hole.
   Fig 3: Drilling Out Threads

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   Important:  All chips must be removed from the drilled hole prior to tapping.

7. Using compressed air, clean out any chips.
   Fig 4: Cleaning Hole

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   Important: 

   • During the tapping process, it is necessary to repeatedly remove the tap and clean chips from the hole and the flutes of the tap.
   • Ensure the tap has created full threads at least to the depth equal to the insert length.
8. Using a suitable tapping wrench, tap the threads of the drilled hole.
   Fig 5: Tapping Threads Of Drilled Hole

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9. In order to tap the new threads for the insert to the proper depth, rotate the tap into the cylinder head bolt hole until the second mark (1) on the tap aligns with the top of the drill bushing (3).
   Fig 6: Identifying Tap Markings

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   Important:  Remove the fixture plate prior to installing the insert with the installer tool.

10. Remove the fixture plate bolts (1).
11. Remove the fixture plate (3) and bushing (1).
    Fig 7: Removing Fixture Plate & Bushing

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    Important:  All chips must be removed from the tapped hole prior to insert installation.

12. Using compressed air, clean out any chips.
    Fig 8: Cleaning Hole

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13. Spray cleaner GM P/N 12346139, P/N 12377981 or equivalent into the tapped hole.
    Fig 9: Spraying Cleaner Into Tapped Hole

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    Important:  All chips must be removed from the tapped hole prior to insert installation.

14. Using compressed air, clean out any chips.
    Fig 10: Cleaning Hole

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    Important:  Do not allow oil or other foreign material to contact the outside diameter (OD) of the insert.

15. Lubricate the threads of the driver installation tool (2) with the driver oil (1) J 42385-110.
    Fig 11: Lubricating Driver Installation Tool Threads

    Courtesy of GENERAL MOTORS CORP.
16. Install the insert (2) onto the driver installation tool (1).
    Fig 12: Installing Insert On Driver Installation Tool

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17. Apply threadlock sealant GM P/N US 12345493 Canada 10953488, J 42385-109, LOCTITE 277® or equivalent (1) to the insert OD threads (2).
    Fig 13: Applying Threadlock To Insert Threads

    Courtesy of GENERAL MOTORS CORP.
18. Install the insert and installation driver (1) into the tapped hole.
19. Start the insert into the threaded hole.

    Important:  If the insert will not thread down until the flange contacts the counterbored surface remove the insert immediately with a screw extracting tool and inspect the tapped hole for any remaining chips and/or improper tapping.

20. Install the insert until the flange of the insert contacts the counterbored surface.

    Important:  The driver installation tool will tighten up before screwing completely through the insert. This is acceptable. The threads at the bottom of the insert are being formed and the insert is mechanically locking the insert into the base material threads.

Fig 14: Installing Insert and Installation Driver Into Tapped Hole
Courtesy of GENERAL MOTORS CORP.
21. Continue to rotate the driver installation tool through the insert.
22. Inspect the insert for proper installation into the tapped hole.