Ford 6.7L Power Stroke Diesel EGR Tube & Fuel Injector Broken Bolts - Nino/Nico Combo Kit

Thank you for investing in the ProMAXX® EGR Valve Tube Repair Kit (NINO). This device was engineered to facilitate a repair, versus replacement of the manifold in the Ford 6.7L diesel engine saving you valuable time and your operation unnecessary cost.

BEFORE THE REPAIR: Depending on the size of your angle drill, you may need to move the intake manifold to the side of the bolt closest to the intake is broken. Protect all air intake passages from cutting debris before performing any machining operation.

• Remove any portion of the fastener that protrudes above the surface of the exhaust manifold prior to mounting the NINO™ ProBody™. Insert the ProBody™ flange side into the EGR passage in the exhaust manifold carefully centering the two bushing mounting holes over the 6MM tapped hole/damaged bolt(s). If only one bolt is broken, use the included ProPin™ PPP2750 for aligning the tool precisely over the damaged bolt. Using a 9/16” deep socket and ratchet or boxed end wrench, tighten the chrome hex nut until the ProBody™ stops moving. Once stable, turn an additional one-half turn or more until the ProBody™ assembly is firmly secure to the manifold.
• Insert ProBushing™ PPB5125 into the ProBody™ over the damaged bolt (Figure 1) and insert the ProDrill™ SSSC125 machine grade tooling bit just ⅜” into your drill chuck of a ½” capacity air or electric drill. Bump or toggle your drill on and off for at least five one second intervals to “seat” the tooling bit prior to drilling continually. Regulate speed to approximately 500-600 RPM for the SSSC125, and 250 RPM for both the SSSC270/420. When using the SSSC270/420, mark a depth 1 3/4 inch from the cutting tip of the bit to the ProDrill™ shank with a marker or tape to control depth of cut. Place one drop of ProMAXX® ProLube™ specially formulated cutting fluid to the bushing and to the bit and manually turn your drill chuck until the tooling bit rests on the damaged bolt.
• Remove and replace the SSSC125 tooling bit with the SSSC270 bit (PMXSSSC280 for 100 Series), (or optional SSSC188/PPB5188 for faster repair times and longer bit life) the PPB5125 bushing with the PPB5270 bushing, and repeat the process above. Repeat with the SSSC420/ PPB5240. Clear all debris and insert the PPB5485N ProBushing™ and attach a 3/8” drive tap holder to the ProTap™ PPT012 and apply two drops of ProMAXX® ProLube™ to the tap. Insert the ProTap™ PPT012 into the bushing, slowly and carefully turning the tap by hand first clockwise ¼ turn, then counterclockwise ¼ turn, blow down the flutes of the tap to clean debris frequently and repeat this process until the tap stops cutting.
• Remove the ProBody™ assembly by loosening the chrome hex nut and lightly tap the top of the ProArbor™ with a plasticfaced hammer to unlock it from the manifold.
• Apply one drop of Loctite® (PMXTLF014) to the PPS006B black oxide coated ProSert™. Thread the PPS006B ProSert™ onto the Insert Tool then into the manifold until it stops flush. Once locked, the manifold is now permanently repaired (Figure 2). ProMAXX® recommends adding Permatex anti-seize compound to the fasteners when re-installing the EGR tube for easier repairs in the future.

Nino User Guide PDF

FORD 6.7L DIESEL BROKEN FUEL INJECTOR BOLT TOOL KIT - NICO

Thank you for investing in the ProMAXX® NICO fuel injector hold-down bolt repair kit. It is designed as a complete system to ensure successful repair of the cylinder head without removal.

This is a critical machining operation. It is imperative you follow the instructions precisely to get the best results.

• Remove fuel lines and fuel injectors (using ProMAXX® PowerPull fuel injector puller PMXPWP100PRO) and set aside.
• Remove the valve cover and only those corresponding valve train components necessary to gain access to the broken injector hold-down bolt.
• Cover and protect all open cylinder head cavities from cutting debris. Remove any remaining portion of the fastener that protrudes above the surface of the cylinder head. Thoroughly clean the injector passage hole with an appropriate solvent prior to mounting NICO.
• Once cleaned, insert NICO into the injector passage of the cylinder head with the nylon flange side down between the two exhaust valves as shown below.
• Using a 9/16” wrench or socket, hand tighten the chrome hex nut until NICO is securely anchored in the cylinder head so it does not move. Once anchored, turn the hex nut one additional half rotation and insert ProBushing PPB5125 until it seats.

Avoid using an electric/air-powered ratchet as damage to the NICO expandable flange will result.

• Check the depth of the open injector hold-down-bolt and mark your tooling bit approximately two (2) inches from the point of the drill bill up the shank. Mark it with a line or tape to ensure proper clearance to eliminate damage to the cylinder head.
• Insert the ProDrill SPJC125 bit into a 3/8” capacity air drill. Place the bit through the cap of the ProLube bottle and gasket. For subsequent steps, place just one drop on the end of the ProDrill and ProBushing, and repeat as necessary.
• Before drilling continuously, IT IS CRITICAL to toggle, or bump, your drill on/off for five one-second intervals while applying light pressure. This process will maintain precise alignment by creating a “seat” or “divot” for the drill bit preventing the bit from walking or drifting off-center.
• Begin drilling continuously according to the enclosed drill speed chart. Remove and replace the bushing/bit PPB5125/SPJC125 with PPB5188/SPJC188, PPB5266/SPJC266 and repeat the steps above. Replace PPB5266 with PPB5320 and using a 3/8” drive tap holder or tap handle, attach the ProTap PPT008. Add one drop of ProLube to each flute of the tap and begin chasing the threads by slowly turning the tap clockwise then counterclockwise, a half-turn at a time, stopping frequently to force compressed air down the flute to clean the tap. Repeat this process frequently and carefully until the tap stops cutting.

CAUTION: DO NOT OVER-TORQUE TAP.

• Remove NICO from the cylinder head by loosening the chrome nut and then lightly tap the top of the nut with a plastic-faced hammer to unlock it from the cylinder head. In the unlikely event a tap is fractured, contact ProMAXX® technical support.

OPTIONAL PROKIT PLUS USERS FOR THREAD REPAIR- Utilize the ProBushing PPB5420 with ProDrill SSSC420 and ProBushing PPB5485 with ProTap PPT012 and repeat the “stepped” machining process above. Add one drop of locking fluid (red) to the insert PPS008 and using the insert tool (PPSTOLNIC) complete the installation.

All ProMAXX® tooling included in your kit is specifically engineered to a controlled precision tolerance of (+) .000”/ (-).001”. ProMAXX® Tool only uses machine-shop-grade tooling to deliver accurate and repeatable results. ProMAXX® Tool proudly provides limited lifetime warranties and free unlimited technical support. For more information, replacement parts, or to submit comments or questions visit www.promaxxtool.com. For technical support contact (724) 941-0941.

ProMAXX® warrants this product to the original purchaser for its useful life against deficiencies in material and workmanship. This LIMITED LIFETIME WARRANTY does not cover normal wear and tear, and if it is used incorrectly, abused, altered or repaired. Deficient products will be replaced or repaired.

Always use OSHA-approved safety glasses/goggles and protective gloves while using this device and performing this operation.

Nico User Guide PDF

Invest In Excellence

The Nino/Nico Combo Kit is not just a purchase, but an investment in excellence. Experience a new pinnacle of diesel repair efficiency and effectiveness. Order the Nino/Nico Combo Kit today and step into a realm of unmatched repair convenience and reliability.