[KA24DE] Room for helicoils in lower timing cover?

[slipnfall]

[ 1992 Nissan 240sx, KA24DE engine. Front cover oil pan bolts stripped out. ]

Hi folks, I replaced my oil pan a few weeks back(it was cracked and leaked+I installed an -8AN oil return bung), but now I'v developed another leak. The problem is the front two oil pan bolts stripped out in the front cover(aluminum). I must have unknowingly stipped them previously when I assembled the motor, but it didn't leak b/c there was a good seal(it was assembled upside down, so gravity+the liq. gasket helped me here.)

Anyways, can anyone say for sure if there's room for helicoils in that area of the front cover? I *really* don't want to go through the hassle of replacing the entire cover, b/c it is brand new, with a new front oil seal. I was hoping to just drop the pan again, and helicoil it while still installed. I considered maybe just using a size larger screw, but I would risk cracking the cover. IIRC, those bolts are 10x1.25, and I still have 2-3 helicoils left from when I did my valve cover threads.

Suggestions? Pulling the pan wasn't all that bad of a job... the hardest part was re-applying a consistant bead of liq. gasket after I mucked it up reaching in for the pickup tube bolts. I used a sensor-safe permatex RTV(bad decision, I had a new tube, didn't feel like running to get something else), but I plan on using Hi-temp Red RTV next time. Tips?

Thanks for reading,Jamie

PS-here's a picture of the pan I installed for your viewing pleasure.

[NISTECH]

If your talking about the 2 bolts going into the front of the pan upwards into the timing cover they a 6x1.00 There is really not enough meat on the outside of the cover for a heli coil. if you could thread the hole for a smaller bolts helicoil you would probably be ok. and just use slightly larger washers on the smaller bolts to attach the pan.

[slipnfall]

Oh duh, yeah you're right: 10mm is wayy to big... that was just the first # that came to mind. And yes those are the two bolts you assumed.

Anyhoo, I think the drill bit size for the 6x1 was 1/8", but I'm not sure on the tap size. The problem is if I go to, say a 5x1 helicoil, will there be enough material for that helicoil to grab to? I'll have to look at my kit next week and see how wide the tap for a 6x1 is... the problem is I just don't have another front cover to see how thick it really is.

[NISTECH]

When you get the pan off look at the cover from the inside, you will see the bosses for where the bolts go in. That will give you an idea just how thin the front cover is around those bolts. What happens is the bolts essentially hydro lock in the hole from having silicone on top of the threaded area. The holes arent deep enough to allow for the old dryed up peaks of silcone on the tip and new silicone that gets shoved in there when you insert the bolt. You need to pick off that dried up silcone peak so the tip of the bolt is clean. Then once you have the pan in place place the bolt in the hole and take it back out to wipe off the wet silcone that stickes to the tip of the bolt. Then insert it and tighten it. This will prevent the hydrolock in the hole and prevent you fron stripping the threads from the cover.

[slipnfall]

Oh, well I didn't remember they were just bosses... yeah that really limits the room for a helicoil I suppose. I'll see what size helicoil I can get, and what size clearance hole it requires...Thanks for the tip on the screws, I never considered that it was the silicon that caused them to strip.

Regards,Jamie