LEMON Manuals: Even more car manuals for everyone
Home >> Chevrolet >> 2004 >> Malibu Maxx >> Repair and Diagnosis >> External Pages >> Different car >> Section 238 (Engine Mechanical - 3.6L (Ly7) (Repair Instructions - 4 Of 5)) >> Off-Vehicle Repair Instructions (Part 3) >> Thread Repair >> Inboard Bolt Holes

Inboard Bolt Holes

WARNING: This page is about a different car, the 2006 Buick LaCrosse and 2006 Buick Allure. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: Refer to Safety Glasses Caution in Cautions and Notices.
IMPORTANT:
  • Ensure the fixture plate is installed during the machining and installation processes of the insert.
  • 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, 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.

    Fig 1: Positioning Fixture Plate
    GM1379785Courtesy of GENERAL MOTORS CORP.
  1. Position the fixture plate (3) with the bushing (1) installed over the crankshaft main cap bolt hole to be repaired.
  2. Loosely install the fixture plate bolts (2) into the remaining crankshaft main cap bolt holes.
    3. Fig 2: Locating Alignment Pin
    GM1379787Courtesy of GENERAL MOTORS CORP.
  3. Position the alignment pin (1) through the bushing and into the crankshaft main cap bolt hole.
  4. With the alignment pin in the desired crankshaft main cap bolt hole, tighten the fixture retaining bolts (2).
  5. Remove the alignment pin (1) from the crankshaft main cap bolt hole.
    6. Fig 3: Drilling Out Damaged Threads
    GM1379790Courtesy of GENERAL MOTORS CORP.
    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 crankshaft main bolt hole until the mark (1) on the drill aligns with the top of the drill bushing (2).
  6. Drill out the threads of the damaged hole.
    7. Fig 4: Cleaning Out Metal Chips
    GM623361Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: All chips must be removed from the drilled hole prior to tapping.
  7. Using compressed air, clean out any chips.
    8. Fig 5: Positioning Tapping Wrench
    GM1379793Courtesy of GENERAL MOTORS CORP.
    IMPORTANT:
    • Do not remove the fixture plate, ensure the fixture plate is installed during the machining and installation processes of the insert.
    • 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 by hand only.
    9. Fig 6: View Of Fixture Plate, Drill Bushing & Tool Marking
    GM377635Courtesy of GENERAL MOTORS CORP.
  9. In order to tap the new threads for the insert to the proper depth, rotate the tap into the crankshaft main cap bolt hole until the mark (3) on the tap aligns with the top of the drill bushing (2).
    10. Fig 7: Cleaning Out Metal Chips
    GM623361Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: All chips must be removed from the tapped hole prior to insert installation.
  10. Using compressed air, clean out any chips.
    11. Fig 8: Spraying Cleaner Into Tapped Hole
    GM623364Courtesy of GENERAL MOTORS CORP.
  11. Spray cleaner GM P/N 12346139, GM P/N 12377981 (Canadian P/N 10953463) or equivalent into the tapped hole.
    12. Fig 9: Cleaning Out Metal Chips
    GM623361Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: All chips must be removed from the tapped hole prior to insert installation.
  12. Using compressed air, clean out any chips.
    13. Fig 10: Lubricating Installer Tool Using Driver Oil
    GM313562Courtesy of GENERAL MOTORS CORP.
    IMPORTANT:
    • Do not remove the fixture plate, ensure the fixture plate is installed during the installation process of the insert.
    • Do not allow oil or other foreign material to contact the outside diameter (OD) of the insert.
  13. Lubricate the threads of the driver installation tool (2) with the driver oil (1) J 42385-110.
    14. Fig 11: View of Bushing Type Insert
    GM313567Courtesy of GENERAL MOTORS CORP.
  14. Install the insert (2) onto the driver installation tool (1).
    15. Fig 12: Applying Threadlock To Insert
    GM313572Courtesy of GENERAL MOTORS CORP.
  15. Apply threadlock sealant GM P/N 12345493, (Canadian P/N 10953488), J 42385-109, LOCTITE 277®, or equivalent (1) to the insert OD threads (2).
    16. Fig 13: Insert & Installation Driver
    GM1379796Courtesy of GENERAL MOTORS CORP.
  16. Install the insert and installation driver into the tapped hole by hand only.
  17. Start the insert into the threaded hole.
    18. 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.
  18. Install the insert until the flange of the insert contacts the counterbored surface.
    19. 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.
  19. Continue to rotate the driver installation tool through the insert.
    20. Fig 14: View Of Fixture Plate, Drill Bushing & Tool Marking
    GM377635Courtesy of GENERAL MOTORS CORP.
  20. Rotate the driver installation tool until the mark (3) on the driver installation tool aligns with the top of the drill bushing (2).
  21. Inspect the insert for proper installation into the tapped hole.
    22. Fig 15: Positioning Fixture Plate
    GM1379785Courtesy of GENERAL MOTORS CORP.
  22. Remove the fixture plate bolts (2).
  23. Remove the fixture plate (3) and bushing (1).
scientia non olet · About LEMON Manuals