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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 427 (Engine Mechanical - 4.8L, 5.3L, & 6.0L (Unit Repair)) >> 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 Components
    G01674852Courtesy of GENERAL MOTORS CORP.
    CAUTION: Refer to SAFETY GLASSES CAUTION in Cautions and Notices.
    IMPORTANT: The use of a cutting type fluid GM P/N United States 1052864, GM P/N Canada 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: Fixture Plate, Bolts & Bushing
    G01674853Courtesy 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
    G01674854Courtesy 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: Cylinder Head Bolt Identification
    G01674855Courtesy of GENERAL MOTORS CORP.
  7. Install the sleeve (2) onto the drill (1), if required.
    Fig 5: Drill & Sleeve
    G01674856Courtesy 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 Threads Of Cylinder Head Bolt Hole
    G01674857Courtesy of GENERAL MOTORS CORP.
  10. Using a tap wrench, tap the threads of the drilled hole.
    Fig 7: Tapping Threads Of Cylinder Head Bolt Hole
    G01674858Courtesy 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.
    Fig 8: Fixture Plate, Bushing & Depth Marks
    G01674859Courtesy of GENERAL MOTORS CORP.
  14. Spray cleaner GM P/N United States 12346139, GM P/N Canada 10953463, GM P/N United States 12377981, GM P/N Canada 10953463, or equivalent, into the hole.
  15. 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.
  16. Lubricate the threads of the installer tool (2) with the driver oil (1).
    Fig 9: Lubricating Installer Tool Threads
    G01674860Courtesy of GENERAL MOTORS CORP.
  17. Install the insert (2) onto the driver tool (1).
    Fig 10: Driver Tools & Insert
    G01674861Courtesy of GENERAL MOTORS CORP.
  18. Apply threadlock LOCTITE® 277, J 42385-109 (1), or equivalent to the insert OD threads (2).
    Fig 11: Applying Threadlock To Insert
    G01674862Courtesy 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: Installing Insert & Driver Into Cylinder Head Bolt Hole
    G01674863Courtesy of GENERAL MOTORS CORP.
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