Crankshaft Main Bolt Hole Thread Repair - Suzuki XL7 2007 Service Manual

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.
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.

Crankshaft Main Bolt Hole Thread Repair

Special tool
J 42385-700 High Feature Thread Repair Kit
J 42385-2000 Thread Insert Kit
NOTE
• In order to repair some crankshaft main
bolt holes it will be necessary to mount the
fixture plate upside down.
• Do NOT remove the fixture plate prior to
installing the insert with the installation
driver. The fixture plate remains in position
throughout the thread repair process.
The crankshaft main bearing bolt hole thread repair
tooling are in the kits J 42385-2000 and J 42385-700.
The crankshaft main bearing bolt hole thread repair
components consist of the following:
• J 42385-702 Drill (1) for outboard holes
• J 42385-703 Tap (2) for outboard holes
• J 42385-704 Installation driver (3) for outboard holes
• J 42385-726 Bushing (4) for outboard holes
• J 42385-727 Alignment pin (5) for outboard holes
• J 42385-728 Bolts (6) for outboard holes
• J 42385-720 Drill (7) for inboard holes
• J 42385-721 Tap (8) for inboard holes
• J 42385-722 Installation driver (9) for inboard holes
• J 42385-713 Bushing (10)
• J 42385-308 Alignment pin (11)
• J 42385-734 Bolts (12)
• J 42385-712 Fixture plate (13)
Engine Mechanical: 1D-239