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Home › Saturn › 2002 › L300 › Repair and Diagnosis › External Pages › Different car › Section 298 (Engine Mechanical) › Repair Instructions › Off Vehicle Repair Instructions › Thread Repair - Main Cap Bolt Hole › Thread Repair Kit

Thread Repair Kit

WARNING: This page is about a different car, the 2003 Saturn LW200 and 2003 Saturn L200. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: View of Self-locking Insert
GM896715Courtesy of GENERAL MOTORS CORP.

The Time Sert® thread repair process involves a solid bushing type insert. The insert is made of carbon and is self-locking. During the bushing installation process, the driver tool expands the bottom external threads of the insert into the base material. This action mechanically locks the insert in place. Also when installed to the proper depth, the flange of the insert will be seated against the counter-bore of the repaired hole.

CAUTION: Standard shop practices, particularly eye protection, should be followed during these operations to avoid personal injury.
IMPORTANT: The use of a cutting type fluid GM P/N 1052864, WD 40®, or equivalent is recommended when performing drilling, counter-boring, and tapping procedures.
Fig 2: View of Driver Tool
GM896710Courtesy of GENERAL MOTORS CORP.

Driver oil must be used on installer driver tool.

The tool kits are designed for use with either a suitable tap wrench or drill motor.

  1. Drill out threads of damaged hole.
    • M6 inserts require a minimum drill depth of 15 mm (0.59 in).
    • M8 inserts require a minimum drill depth of 20 mm (0.79 in).
    • M10 inserts require a minimum drill depth of 23.5 mm (0.93 in).
  2. Using compressed air, clean out any chips.
    3. Fig 3: Counter-boring Hole
    GM896620Courtesy of GENERAL MOTORS CORP.
  3. Counter-bore hole to full depth permitted by tool.
  4. Using compressed air, clean out any chips.
    5. Fig 4: Tapping Threads of Drilled Hole
    GM896626Courtesy of GENERAL MOTORS CORP.
  5. Using a tap wrench, tap threads of drilled hole.
    • M6 inserts require a minimum tap depth of 15 mm (0.59 in).
    • M8 inserts require a minimum tap depth of 20 mm (0.79 in).
    • M10 inserts require a minimum tap depth of 23.5 mm (0.93 in).
  6. Using compressed air, clean out any chips.
  7. Spray cleaner GM P/N 12346139, P/N 12377981 or equivalent into holes.
  8. Using compressed air, clean any cutting oil and chips out of drilled hole.
    9. Fig 5: Applying Lubricant to Threads of Installer Tool
    GM896716Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Do not allow oil or other foreign material to contact outside diameter (OD) of insert.
  9. Lubricate threads of installer tool with drive oil.
    10. Fig 6: Installing Insert to Installer Tool
    GM896719Courtesy of GENERAL MOTORS CORP.
  10. Install insert onto installer tool.
    11. Fig 7: Applying High Strength Threadlock Red to Insert OD Threads
    GM896717Courtesy of GENERAL MOTORS CORP.
  11. Apply High Strength Threadlock Red, J42385-109 or equivalent to insert OD threads.
    12. Fig 8: Installing Insert
    GM896714Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Installer tool will tighten up before screwing completely through insert. This is acceptable. You are forming bottom threads of insert and mechanically locking insert to base material threads.
  12. Install insert into hole.
    1. Install insert until flange of insert contacts counter-bored surface.
    2. Continue to rotate installer tool through insert.
    13. Fig 9: View of Properly Installed Insert
    GM896715Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: A properly installed insert will be either flush or slightly below flush with surface of base material.
  13. Inspect insert for proper installation into hole.
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