Cylinder Head Bolt Hole Thread Repair

Special Tool 

J 42385-700 High Feature Thread Repair Kit 

J 42385-2000 Thread Insert Kit 

Fig 1: Identifying Cylinder Head Bolt Hole Thread Repair Tool Kit

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The cylinder head bolt hole thread repair tooling are in the kits J 42385-2000 and J 42385-700. The cylinder head bolt hole thread repair components consist of the following:

• J 42385-723 Drill (1)
• J 42385-724 Tap (2)
• J 42385-725 Installation driver (3)
• J 42385-303 Alignment pin (4)
• J 42385-302 Bushing (5)
• J 42385-733 Bolts (6)
• J 42385-401 Fixture plate (7)

When installed to the proper depth, the flange of the insert will be seated against the counterbore of the drilled/tapped hole.

Fig 2: Positioning Fixture Plate With Bushing Installed Over Cylinder Head Bolt Hole

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1. Position the fixture plate (3) with the bushing (1) installed over the cylinder head bolt hole to be repaired (4).
2. Loosely install the fixture plate bolts (2) into the remaining cylinder head bolt holes.
   Fig 3: Identifying Alignment Pin And Fixture Retaining Bolts

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3. Position the alignment pin (1) through the bushing and into the cylinder head bolt hole.
4. With the alignment pin in the desired cylinder head bolt hole, tighten the fixture retaining bolts (2).
5. Remove the alignment pin (1) from the cylinder head bolt hole.
   Fig 4: 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 hole until the stop collar contacts the top of the drill bushing.
6. Drill out the threads of the damaged hole.
   Fig 5: Cleaning Out Chips From Drilled Hole Using Compressed Air

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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 6: Tapping Threads Of Drilled Hole By Hand Only

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   NOTE:

   • 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 7: Identifying Mark On Tap And 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 cylinder head bolt hole until the mark (3) on the tap aligns with the top of the drill bushing (2).
   Fig 8: Identifying Fixture Plate, Bolts And Bushing

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   NOTE: Remove the fixture plate prior to installing the insert with the installer tool.
10. Remove the fixture plate bolts (2).
11. Remove the fixture plate (3) and bushing (1).
    Fig 9: Cleaning Out Chips From Tapped Hole Using Compressed Air

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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: Spraying Cleaner GM P/N 12346139, GM P/N 12377981 Into Tapped Hole

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13. Spray cleaner GM P/N 12346139, GM P/N 12377981 (Canadian P/N 10953463) or equivalent into the tapped hole.
    Fig 11: Cleaning Out Chips From Drilled Hole Using Compressed Air

    Courtesy of SUZUKI OF AMERICA CORP.
    NOTE: All chips must be removed from the tapped hole prior to insert installation.
14. Using compressed air, clean out any chips.
    Fig 12: Lubricating Threads Of Driver Installation Tool With J 42385-110

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    NOTE: Do not allow oil or other foreign material to contact the outside diameter (OD) of the insert.
15. Lubricate the threads of the driver installation tool (2) with the J 42385-110 (1).
    Fig 13: Identifying Insert And Driver Installation Tool

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16. Install the insert (2) onto the driver installation tool (1).
    Fig 14: Applying Threadlock Sealant GM P/N 12345493, J 42385-109, LOCTITE 277® To Insert OD Threads

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17. 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 15: Identifying Insert And Installation Driver

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18. Install the insert and installation driver (1) into the tapped hole by hand only.
19. 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.
20. 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.
21. Continue to rotate the driver installation tool through the insert.
    Fig 16: Rotating Driver Installation Tool Through Insert Until Mark On Driver Installation Tool Aligns With Surface Of Engine Block Deck

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22. In order to completely form the new threads in the insert, rotate the driver installation tool through the insert until the mark (1) on the driver installation tool aligns with the surface of the engine block deck (2).
23. Inspect the insert for proper installation into the tapped hole.