Thread Repair Using TimeSert® Thread Repair Kit

Quick Training Guide – QT114A

Stripped or damaged threads in engine component bolt holes may be repairable using the TimeSert® Thread
Repair Kit. This Quick Training Guide describes how to install the TimeSert® thread repair insert.

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©Toyota Motor Sales, U.S.A., Inc., September 15, 2014

 Toyota Thread Repair Using TimeSert® Thread Repair Kit
Quick Training Guide QT114A
Overview TimeSert® Kit Inspection Preparation Setup Drilling Tapping Installing

Click the tabs at the top to view each section

Overview
When the threads in an engine component bolt hole become stripped or
damaged, it may be possible to repair the bolt hole using a thread insert.
The repair process involves drilling out the bolt hole to a slightly larger
diameter, tapping the hole, and then installing an appropriately-sized Precautions
thread repair insert in the hole.
• Protective goggles, a protective mask, and other necessary
The basic installation steps are: protective equipment must be worn while working

• Inspecting the components and bolts for serviceability • Brake cleaner is highly flammable; do not use it near fire or
hot components
• Fastening the drill fixture to the component (when applicable)
–– If you get brake cleaner on your clothes, keep away from
• Drilling out the damaged bolt hole fire and hot components until clothes are dry
• Tapping the bolt hole –– Be careful to prevent spattering while working
• Installing the insert –– For details, refer to the brake cleaner’s handling instructions

Before installing a TimeSert® kit in a Toyota engine, check

for applicable Technical Service Bulletins.

Drill out Tap the hole Install the insert Repair Complete
damaged threads

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 Toyota Thread Repair Using TimeSert® Thread Repair Kit
Quick Training Guide QT114A
Overview TimeSert® Kit Inspection Preparation Setup Drilling Tapping Installing

Click the tabs at the top to view each section

The TimeSert® Kit
TimeSert® kits and components may be ordered by calling Approved
Dealer Equipment (ADE) at 1-800-368-6787. 

When ordering, be sure to specify:

• The correct size (for example, M11 x 1.5 x 30mm)
• The number of inserts needed

Insert (x10)

Drill Bushing

Alignment Pin

Loctite®

Long Bolt (x2) Drill Fixture Core Dril Tap Insert Driver Driver Oil

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 Toyota Thread Repair Using TimeSert® Thread Repair Kit
Quick Training Guide QT114A
Overview TimeSert® Kit Inspection Preparation Setup Drilling Tapping Installing

Click the tabs at the top to view each section

Inspection
With the engine removed from the vehicle and mounted on an engine Example: Measuring the Cylinder Head for Flatness
stand, disassemble the engine to gain access to the necessary
components. Perform the following inspections:
• Measure the component mating surfaces for flatness
• Measure the bolts for stretch

Example: Measuring the Cylinder Block for Flatness

Using a precision straightedge and feeler gauge, measure the cylinder

head contact surface for flatness.

Using a precision straightedge and feeler gauge, measure the cylinder

head contact surface for flatness. If the Warpage exceeds Repair Also measure the intake and exhaust manifold contact surfaces
Manual specifications, replace the short block assembly instead of for flatness.
attempting to repair it.
If the warpage exceeds Repair Manual specifications, replace the
Example: Measuring Cylinder Head Bolts component instead of attempting to repair it.

Using a caliper, measure the length of the head bolts from the seat
to the end. If any bolt exceeds Repair Manual specifications, replace
the bolt.

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 Toyota Thread Repair Using TimeSert® Thread Repair Kit
Quick Training Guide QT114A
Overview TimeSert® Kit Inspection Preparation Setup Drilling Tapping Installing

Click the tabs at the top to view each section

Preparation
Attach the engine or engine component to the engine stand and make Before beginning work:
sure that it can be rotated.
• Clean off any cutting particles or other substances from the tools
that will be used

• Remove any oil or other substances from the component surface

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 Toyota Thread Repair Using TimeSert® Thread Repair Kit
Quick Training Guide QT114A
Overview TimeSert® Kit Inspection Preparation Setup Drilling Tapping Installing

Click the tabs at the top to view each section

Setup
1. Align the Drill Fixture 2. Fasten the Drill Fixture
When applicable, attach the drill fixture to the engine component you’re a. Press the alignment pin gently and make sure that the pin is
working on. inserted all the way down into the hole.
a. Align the round hole of the drill fixture with the bolt hole which Press gently
will be repaired.
b. Install the drill bushing and alignment pin, and then temporarily
install 2 bolts to fix the drill fixture.

Align drill bushing and

Alignment Pin
alignment pin with bolt hole

Drill Bushing b. Hold the drill fixture so that it does not become displaced, and
Head Bolt tighten the 2 bolts.
Head Bolt Hold in place
while tightening

Drill Fixture

When repairing bolt holes in the cylinder block: c. Remove the alignment pin, and visually check that the bolt hole
• Move the pistons from the Top Dead Center position in and drill fixture are centered.
order to avoid contact between pistons and drill fixture
• Always use 2 bolts to fix the drill fixture
CAUTION: If the drill fixture is NOT correctly centered, the
• Avoid using bolt holes with damaged threads for
bolt holes may be drilled at an angle, and the component
this procedure and install the bolts diagonally
will need to be replaced.
whenever possible

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 Toyota Thread Repair Using TimeSert® Thread Repair Kit
Quick Training Guide QT114A
Overview TimeSert® Kit Inspection Preparation Setup Drilling Tapping Installing

Click the tabs at the top and side to view each section
Drilling: Protect the Component

Protect the Component

If the cutting particles that are produced during the drilling and tapping
process enter the engine, they can cause engine damage, so be sure to
apply protection.

Example:
When repairing the cylinder block, use tape or a shop cloth to cover the
parts shown and protect the cylinder block so that cutting particles do
NOT enter: Bolt Holes

• Drill fixture bolt holes

Drill the Bolt Hole

Tape
• Top surface of the cylinder block
Shop Cloth
• Cylinder block component installation holes

Use a new shop cloth and tape for each repair as the
old ones may have cutting particles attached to them.

Component
Installation Holes

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 Toyota Thread Repair Using TimeSert® Thread Repair Kit
Quick Training Guide QT114A
Overview TimeSert® Kit Inspection Preparation Setup Drilling Tapping Installing

Click the tabs at the top and side to view each section
Drilling: Drill the Bolt Hole

Protect the Component

1. Tilt the component being repaired so that the cutting particles will 3. Remove the core drill and drill bushing. Invert the component so
fall away from the component. that it is upside-down. 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.

Drill the Bolt Hole

2. Use the core drill and drill the bolt hole.

CAUTIONS: 4. Return the component to a tilted position and continue drilling in

• Hold the drill perpendicular to the top surface of the component. steps until you reach the bottom of the hole.
If the bolt holes are drilled at an angle, the component will need
to be replaced.
• Drill the hole in 4 progressively deeper steps, retracting the drill
each time, to clear the cutting particles from the hole.
Drill in 4 steps. Do not
• Apply WD-40® regularly to lubricate the drill. drill in one step.
Core Drill

P O

Drill perpendicular
to mating surface
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 Toyota Thread Repair Using TimeSert® Thread Repair Kit
Quick Training Guide QT114A
Overview TimeSert® Kit Inspection Preparation Setup Drilling Tapping Installing

Click the tabs at the top and side to view each section
Tapping: Using the Tap

Using the Tap

1. Position the component vertically, and use the tap and tap handle to Tap
cut new threads in the bolt hole.

CAUTION: Hold the tap

perpendicular to the top

Drying the Bolt Hole & Checking for Leaks

surface of the component.
If the bolt holes are tapped
at an angle, the component
will need to be replaced.

Tap perpendicular to
mating surface

• Tap the hole in 4 progressively deeper steps, retracting the tap 2. Invert the component so that it is upside-down. Insert the nozzle
each time, to clear the cutting particles from the hole. 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.
• Apply WD-40® regularly to lubricate the tap.

P
Tap in 4 steps
O
Do not tap
in 1 step

3. Return the component to a tilted position and continue tapping

in steps until you reach the bottom of the hole.

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 Toyota Thread Repair Using TimeSert® Thread Repair Kit
Quick Training Guide QT114A
Overview TimeSert® Kit Inspection Preparation Setup Drilling Tapping Installing

Click the tabs at the top and side to view each section
Tapping: Drying the Bolt Hole and Checking for Leaks

Using the Tap

Drying the Bolt Hole Checking for Leaks
After the final tap, invert the component and clean the bolt hole. Use an Use a cylinder leak down tester and check the bolt holes.
air blower and dry the hole completely. • 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 hole
• Apply 44 psi (300 kPa) to the bolt hole

Drying the Bolt Hole & Checking for Leaks

• Confirm the air pressure does NOT decrease after 15 seconds

• When repairing a cylinder block, if air leaks through

the bolt hole into the cylinder block, replace the
short block
• Make sure to perform the leak check BEFORE
inserting the insert to the bolt holes

Because Loctite® will be used to fasten the insert in

place, be sure to dry the bolt hole thoroughly while the
component is inverted.

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 Toyota Thread Repair Using TimeSert® Thread Repair Kit
Quick Training Guide QT114A
Overview TimeSert® Kit Inspection Preparation Setup Drilling Tapping Installing

Click the tabs at the top to view each section

Installing
1. Apply a small amount of driver oil to the threads of the insert driver. 4. Insert the insert driver with the insert into the bolt hole and slowly
Insert Driver screw it into the hole.
Driver Oil

Insert Driver Threads

2. Screw the insert onto the insert driver until it stops. Do not apply oil
to the outer threads of the insert.
Near the bottom of the hole, you will begin to feel
resistance as the driver expands the last 3 threads to
lock the insert in place. When the driver begins turning
easily again, the installation is complete. Turn the driver
in the opposite direction and remove it.

Test the Repair

Remove the drill bushing from the fixture. Apply a small amount of
engine oil to the threads of the bolt, and screw the bolt into the hole by
3. Apply a small amount of Loctite® to the outer threads of the insert. hand to verify that there is no problem with the threads.
Loctite® Remove the shop cloth and protective tape, and remove the drill fixture
(when applicable).

Work carefully so the cutting particles do not fall on the engine.

Insert

The insert will not screw all the way onto the driver
because the last few threads of the insert are
unfinished. Installing the insert will finish the last 3
threads and lock the insert in place.
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