SYS.OK|MANUAL.DB● LIVE
HOMESERVICE MANUALSCHEVROLET2006COBALT SS, 4D SEDAN, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 809 (ENGINE MECHANICAL - 2.0L)REPAIR INSTRUCTIONS - OFF VEHICLETHREAD REPAIRMAIN CAP BOLT HOLE THREAD REPAIR
2006 Chevrolet Cobalt SS, 4D Sedan, Standard

Main Cap Bolt Hole Thread Repair

2006 Chevrolet Cobalt SS, 4D Sedan, StandardSECTION Main Cap Bolt Hole Thread Repair
WARNING: This page is about a different car, the 2010 Chevrolet Cobalt. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Identifying Thread Repair Kit Components
    GM313556Courtesy of GENERAL MOTORS CORP.
  1. The main cap bolt hole thread repair kit consists of the following items:
    • Drill (1)
    • Tap (2)
    • Installer (3)
    • Fixture Plate (4)
    • Long Bolts (5)
    • Short Bolts (6)
    • Alignment Pin (7)
    • Bushing (8)
    2. Fig 2: Identifying Alignment Dowel Pins
    GM747194Courtesy of GENERAL MOTORS CORP.
  2. Remove the alignment dowel pins from the holes (1-4), if necessary.
    3. Fig 3: Installing Fixture Plate, Bolt, & Bushing Onto Engine Block
    GM747192Courtesy of GENERAL MOTORS CORP.
  3. Install the fixture plate, bolt, and bushing, onto the engine block.

    Position the fixture plate and bushing over the hole that is to be repaired.

  4. Position the alignment pin in the desired hole and tighten the fixture retaining bolts.
  5. Drill out the damaged hole.
  6. Using compressed air, clean out any chips.
    7. Fig 4: View Of Fixture Plate, Drill Bushing & Tool Marking
    GM377635Courtesy of GENERAL MOTORS CORP.
  7. Using a tap wrench, tap the threads of the drilled hole.

    In order to tap the new threads to the proper depth, rotate the tap into the hole until the mark (3) on the tap aligns with the top of the bushing (2).

  8. Using compressed air, clean out any chips.
  9. Spray cleaner into the hole. Refer to Adhesives, Fluids, Lubricants, and Sealers .
  10. Using compressed air, clean any cutting oil and chips out of the hole.
    11. Fig 5: Lubricating Installer Tool Using Driver Oil
    GM313562Courtesy of GENERAL MOTORS CORP.
RENDER: 1.0x

NO RELATED

Recommended Tools & Savings

Use the Manual With the Right Hardware

Pair factory procedures with proven DIY tools so the instructions are easier to execute.

Affiliate disclosure: We may earn a commission at no extra cost to you.

Shop Manual-Ready ToolsFree Quote CheckQuote Shield Pro

When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.