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Home › Pontiac › 2004 › GTO Automatic › Repair and Diagnosis › Engine Mechanical › Engine Mechanical - 5.7L › Repair Instructions › Off-Vehicle Repair Instructions › Thread Repair › Cylinder Head Bolt Hole Thread Repair

Cylinder Head Bolt Hole Thread Repair

    Fig 1: Identifying Thread Repair Kit Components
    GM313560Courtesy of GENERAL MOTORS CORP.
  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)
    2. Fig 2: Cylinder Head Bolt Tightening Sequence
    GM260150Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: First design engine blocks have different drill and tap depths using both medium length 100 mm (3.94 in) and long 155 mm (6.1 in) M11 cylinder head bolts. Second design engine blocks use only the medium length 100 mm (3.94 in) bolt with a common drill and tap depth.
  2. Measure the depth of the cylinder head bolt holes (1-10) to determine the proper drill and tap depths. Refer to Thread Repair Specifications .
    3. Fig 3: View Of Fixture Plate, Bolts, Bushing & Cylinder Hole
    GM313574Courtesy 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 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.
  3. 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).

    4. Fig 4: View Of Alignment Pin & Fixture Retaining Bolts
    GM313577Courtesy of GENERAL MOTORS CORP.
  4. Position the alignment pin (1) through the bushing and into the hole.
  5. With the alignment pin in the desired hole, tighten the fixture retaining bolts (2).
  6. Remove the alignment pin from the hole.
    7. Fig 5: View Of Stop Collar & Counterbore Drill
    GM313570Courtesy of GENERAL MOTORS CORP.
  7. Install the sleeve (2) onto the drill (1), if required.
    8. Fig 6: Drilling Cylinder Head Bolt Hole
    GM309861Courtesy 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.
    10. Fig 7: Tapping Threads Of Drilled Hole Using Tapping Wrench
    GM320667Courtesy of GENERAL MOTORS CORP.
  10. Using a tap wrench, tap the threads of the drilled hole.
    11. Fig 8: View Of Tap Upper & Lower Marks, Fixture Plate & Bushing
    GM377637Courtesy 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, 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, 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 (Canadian P/N 10953463), 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.
    16. Fig 9: Lubricating Installer Tool Using Driver Oil
    GM313562Courtesy 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).
    17. Fig 10: View of Bushing Type Insert
    GM313567Courtesy of GENERAL MOTORS CORP.
  17. Install the insert (2) onto the driver tool (1).
    18. Fig 11: Applying Threadlock To Insert
    GM313572Courtesy of GENERAL MOTORS CORP.
  18. Apply threadlock LOCTITE™ 277, J 42385-109 (1), or equivalent to the insert OD threads (2).
    19. Fig 12: Installing Insert & Driver Into Cylinder Bolt Hole
    GM320669Courtesy 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.

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