Repair Procedure
1. Attach the cylinder block to the engine stand and make sure that it can be rotated.
2. Clean the tools.
Before beginning work clean oft any cutting particles or other substances from the tools which will be used.
3. Clean the cylinder block.
A. Remove the remaining gasket from the top surface of the cylinder block.
B. Remove any oil or other substances from the top surface of the cylinder block.
4. Mark the core drill positions.
A. Insert a rule into the bolt hole and place the end of the rule against the start of the threads.
B. Mark the position of the top surface of the cylinder block on the rule at this time and record the dimension.
C. Insert the core drill into the drill bushing.
D. Align the rule core drill and bushing positions as shown in the figure. Mark the position of the top surface of the drill bushing on the core drill.
Marking position:
Height of Dimension A + Drill Bushing Height
5. Mark the tap and insert the driver.
A. Align the front tips of the core drill tap and insert driver.
B. Mark the tap and insert driver at the same height as the marking on the core drill.
NOTE
Work carefully so the markings do not rub off during the repair.
6. Provisionally install the drill fixture.
NOTICE
Move the pistons from the Top Dead Center position in order to avoid contact between pistons and drill fixture.
A. Install the drill bushing and alignment pin.
B. Align the round hole of the drill fixture with the bolt hole which will be repaired and then temporarily install 2 head bolts to fix the drill fixture.
7. Center and fasten the drill fixture.
NOTICE
If the drill fixture is NOT correctly centered, the bolt holes may be drilled at an angle, and the cylinder block will need to be replaced.
A. Press the alignment pin gently and make sure that the pin is inserted all the way down into the hole.
B. Hold the drill fixture so that it does not become displaced and tighten the 2 bolts.
C. Remove the alignment pin and visually check that the bolt hole and drill fixture are centered.
8. Protect the cylinder block.
If the cuffing particles that are produced during the drilling and tapping process enter the engine, they can cause engine damage, so be sure to apply protection.
Use tape or a shop cloth to cover the parts shown and protect the cylinder block so that cutting particles do NOT enter it.
^ Drill fixture bolt holes
^ Top surface of the cylinder block
^ Cylinder block component installation holes
NOTICE
Use a new shop cloth and tape for each repair as the old ones may have cutting particles attached to them.
9. Repair the bolt hole.
A. Tilt the cylinder block so that the cutting particles will fall downwards.
B. Use the core drill and repair the bolt hole.
C. Remove the core drill and drill bushing.
D. Invert the cylinder block so that it is upside-down.
E. Insert the nozzle all the way into the bolt hole and spray brake cleaner into the hole in order to flush out the cutting particles from inside it.
F. Return the cylinder block to a tilted position as shown in Figure 23.
G. Repeat steps 9B through 9F until the marking on the core drill is aligned with the top surface of the drill bushing.
10. Tap the bolt hole.
A. Position the cylinder block vertically.
B. Use the tap and tap handle to cut new threads in the bolt hole.
C. Remove the tap and drill bushing.
D. Invert the cylinder block so that it is upside-down.
E. Insert the nozzle all the way into the bolt hole and spray brake cleaner into the hole in order to flush out the cutting particles from inside it.
F. Return the cylinder block to a tilted position as shown in Figure 29.
G. Repeat steps 9B through 9F until the marking on the tap is aligned with the top surface of the bushing.
11. Check the bolt hole.
A. Invert the cylinder block so that it is upside-down.
B. Insert the nozzle all the way into the bolt hole and spray brake cleaner into the hole in order to flush out the cutting particles from inside it.
C. Use an air blower and dry the hole fully.
D. Use a cylinder leak down tester and check the head bolt holes.
(1) Wrap the tip of the tester with seal tape so it is thick enough to fill the gap between the tip of the tester and the holes.
(2) Apply 44 psi (300 kPa) to the head bolt hole.
(3) Confirm the air pressure does NOT decrease after 15 seconds.
NOTICE
^ If air leaks through the head bolt hole into the short block, replace the cylinder block.
^ Make sure to perform the leak check BEFORE inserting the insert to the bolt holes.
12. Install the insert.
A. Apply a small amount of driver oil to the threads of the insert driver.
B. Screw the insert onto the insert driver all the way until it stops.
NOTICE
Do not apply oil to the outer threads of the insert.
C. Apply a small amount of Loctite� to the outer threads of the insert.
D. Insert the insert driver with the insert into the bolt hole and slowly screw it into the hole until the marking on the driver matches the top surface of the drill bushing.
E. When the marking is aligned with the top surface of the bushing turn the driver in the opposite direction to remove it.
F. Remove the drill bushing and screw the head bolt into the hole by hand to verify that there is no problem with the threads.
HINT
Apply a small amount of engine oil to the threads of the head bolt.
G. Remove the shop cloth and protective tape.
NOTICE
Work carefully so the cutting particles do not fall on the engine.
H. Remove the drill fixture.
13. Repeat the insert installation process (steps 2 - 12) on the remaining bolt holes.
NOTE
The insert installation process MUST be performed on all 6 bolt holes regardless of the condition of the bolt hole. (See the Notice in "Precautions for All Operations" in this TSB).
14. Reassemble the engine assembly.
Refer to the applicable model and model year Repair Manual section(s) on TIS.
15. Install the engine assembly into the vehicle.
Refer to the applicable model and model year Repair Manual section(s) on TIS.
16. Test drive to confirm the repair.