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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1619 (Engine Mechanical - 4.8L, 5.3L & 6.0L) >> Repair Instructions >> Off-Vehicle Repair Instructions >> Thread Repair >> Cylinder Head Bolt Hole Thread Repair

Cylinder Head Bolt Hole Thread Repair

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  1. 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: Cylinder Head Bolt Hole Thread Repair Kit
    G02107161Courtesy 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.

  2. 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: Install Fixture Plate, Bolts & Bushing
    G02107162Courtesy of GENERAL MOTORS CORP.
  3. Position the alignment pin (1) through the bushing and into the hole.
  4. With the alignment pin in the desired hole, tighten the fixture retaining bolts (2).
  5. Remove the alignment pin from the hole.
    Fig 3: Alignment Pin & Fixture Retaining Bolts
    G02107163Courtesy of GENERAL MOTORS CORP.
  6. 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
    G02107164Courtesy of GENERAL MOTORS CORP.
  7. Install the sleeve (2) onto the drill (1), if required.
    Fig 5: Installing Sleeve Onto Drill
    G02107165Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: During the reaming process, it is necessary to repeatedly remove the drill and clean the chips from the hole.
  8. 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.

  9. Using compressed air, clean out any chips.
    Fig 6: Drilling Out Damaged Hole
    G02107166Courtesy of GENERAL MOTORS CORP.
  10. Using a tap wrench, tap the threads of the drilled hole.
    Fig 7: Taping Threads Of Drilled Hole Using Tap Wrench
    G02107167Courtesy of GENERAL MOTORS CORP.
  11. 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.

  12. Remove the fixture plate (2), bushing (3), and bolts.
  13. Using compressed air, clean out any chips.
  14. Spray cleaner GM P/N 12346139, GM P/N 12377981 (Canadian P/N 10953463) or equivalent into the hole.
  15. Using compressed air, clean any cutting oil and chips out of the hole.
    Fig 8: Fixture Plate, Bushing & Alignment Marks
    G02107168Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Do not allow oil or other foreign material to contact the outside diameter (OD) of the insert.
  16. Lubricate the threads of the installer tool (2) with the driver oil (1).
    Fig 9: Lubricating Threads Of Installer Tool With Driver Oil
    G02107169Courtesy of GENERAL MOTORS CORP.
  17. Install the insert (2) onto the driver tool (1).
    Fig 10: Installer Tool & Insert
    G02107170Courtesy of GENERAL MOTORS CORP.
  18. Apply threadlock LOCTITE™ 277, J 42385-109 (1), or equivalent to the insert OD threads (2).
    Fig 11: Applying Thread Lock To OD Threads
    G02107171Courtesy of GENERAL MOTORS CORP.
  19. 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: Install Insert & Driver
    G02107172Courtesy of GENERAL MOTORS CORP.
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