Engine & Gearbox Injector clamp bolt thread remedy

Discussion in '7th Generation (2003-2008) [Acura TSX]' started by blackbeard, Thursday 6th Aug, 2015.

  1. blackbeard Club Member ★ ☆ ☆ ☆ ☆

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    Removed injector clamp bolt today in readiness of removing no 1 injector, it only took four or five rotations and it lifted out, complete with what was the last 4 rings or so of alloy thread stuck to it from the casing bolt bore.... the rest of the bore is as bare as a baby's you know what ... great start.

    The injector came out with a little persuasion, it appears to have been keeping itself in place thankfully.

    Does anyone have the spec for these bolts 90019-RBD-E01 they are listed as Special Bolt, (but have no dimensions in the description ie, thread pitch, M9 or whatever etc ), so I can order a helicoil kit to suit , or is there any other ~ better way to deal with this ie tap as is , and next size gauge bolt to suit, or any other method or recommendation ?

    Cheers

    Blackbeard.
     
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  2. Beefy Expert Advisor ★ ★ ★ ★ ★

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    Re-tapping to a bigger bolt causes issues when drilling the injector clamp/collar as it is forged and extremely difficult to drill. I've done it once before but with a specialist oil fed brill bit. Couldn't tell you without measuring the thread pitch or diameter. Once you find that out you can try and find a time sert or helicoil. Could be difficult to get hold of without buying an expensive set. A good machine shop should be able to match you the bolt to the tap/ helicoil you need.
     
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  3. blackbeard Club Member ★ ☆ ☆ ☆ ☆

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    I noticed a wider countersunk type opening in the alloy itself Beefy, there may be a few MIL spare without having to drill the clamp itself, that is assuming this countersunk area is not an insert of some description and of a different material ie harder. It appeared darker but, that may well be just the way it has been machined.

    Being in rural Kent machine shops are far and few between, it looks like I may be re acquainting myself with the public transport system to find a solution, if I can't online.
    I appreciate your reply, many thanks.
     
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  4. Zebster Expert Advisor ★ ★ ★ ★ ★

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    I wonder how much depth of metal is available to allow you to simply drill deeper and use a longer bolt?

    I guess it no longer matters what the original thread was, you can now select whatever best suits whether you get it helicoiled, or have it drilled/re-tapped to whatever bolt you can get through the clamp (whether you have to enlarge the clamp clearance hole or not).
     
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  5. blackbeard Club Member ★ ☆ ☆ ☆ ☆

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    My thoughts also Zebster, the bolt at present just rattles around in the opening, not knowing the option on a repair procedure has caused some confusion.The easiest all in one package for me would have been a helicoil or similar style kit, purely for the convenience of having the drill bit, tap, insert etc all in one package specific to what I needed, and to reuse the existing bolt.

    I can however see the logic in having a tap and die set of varying sizes.

    If I understand correctly, using said tap of suitable size if I were to to simply tap a larger diameter thread into the alloy block as is, and insert the corresponding bolt, that should suffice ?
    As you can tell this type of engineering is not my forte, and of course I need to make the correct effective choice, given the importance of this clamps functionality.
     
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  6. Zebster Expert Advisor ★ ★ ★ ★ ★

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    I don't see why not, except I don't know how much clearance you have in the injector clamp for a larger bolt, and Beefy suggests that making the hole bigger could be a pain.

    Without knowing if the current bolt simply went into a threaded hole in the alloy casting it's hard to be sure though. You seem to think it did, so that should be OK. But if there was previously an insert of some sort then you drilling into it to enlare the receiving thread could obviously make this insert become unstable.
     
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  7. Beefy Expert Advisor ★ ★ ★ ★ ★

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    The next available size bolt up will be too tight for the clamp. Trust me I went through it all as an apprentice. I over tightened the bolt and it just went, pulling the ally out with it. As already discussed you have a few options. Zebster has a good point that it may have been repaired before.. The best way of repairing would be to remove the rocker cover. You can see what you a doing a lot better and the use of a previous heli coil will become obvious
     
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  8. blackbeard Club Member ★ ☆ ☆ ☆ ☆

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    Managed to partially re-drill the clamp bore due to space limitations ~ drill chuck, and got a 6mm helicoil in ,but only part way down, the clamp is tight and has been correctly torqued, no blowback on start up.
    After a spirted test drive, all appears well.

    Thanks to all for the advice.
     
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    Zebster likes this.