Inboard Bolt Holes

Fig 1: Positioning Fixture Plate With Bushing

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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.
   Fig 2: Positioning Alignment Pin Through Bushing

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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.
   Fig 3: Drilling Out Threads Of Damaged Hole

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   NOTE:

   • 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.
   Fig 4: Applying Compressed Air Into Tapped Hole

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   NOTE: All chips must be removed from the drilled hole prior to tapping.
7. Using compressed air, clean out any chips.
   Fig 5: Applying Threads Of Drilled Hole By Hand

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   NOTE:

   • 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.
   Fig 6: Identifying Mark & Drill Bushing

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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).
   Fig 7: Applying Compressed Air Into Tapped Hole

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   NOTE: All chips must be removed from the tapped hole prior to insert installation.
10. Using compressed air, clean out any chips.
    Fig 8: Applying Spray Cleaner Into Tapped Hole

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11. Spray cleaner GM P/N 12346139, GM P/N 12377981 (Canadian P/N 10953463) or equivalent into the tapped hole.
    Fig 9: Applying Compressed Air Into Tapped Hole

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    NOTE: All chips must be removed from the tapped hole prior to insert installation.
12. Using compressed air, clean out any chips.
    Fig 10: Lubricating Threads Of Driver Installation Tool

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    NOTE:

    • 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 J 42385-110 (1).
    Fig 11: Applying Insert Onto Driver Installation Tool

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14. Install the insert (2) onto the driver installation tool (1).
    Fig 12: Applying Threadlock Sealant To Insert OD Threads

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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).
    Fig 13: Applying Threads Of Drilled Hole By Hand

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16. Install the insert and installation driver into the tapped hole by hand only.
17. Start the insert into the threaded hole.
    NOTE: 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.
    NOTE: 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.
    Fig 14: Identifying Mark & Drill Bushing

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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.
    Fig 15: Identifying Fixture Plate & Bolts

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22. Remove the fixture plate bolts (2).
23. Remove the fixture plate (3) and bushing (1).

Reference: ENGINE BLOCK ASSEMBLE .