Power Stroke Package - BRAVO Ford 6.7L Power Stroke Fuel Injector Hold Down Bolt Repair ProKit And Fuel Injector Puller

Fuel Injector Hold Down Bolt User Guide Text

USER GUIDE: Thank you for investing in the ProMAXX® NICO™ fuel injector hold-down bolt repair kit. We engineered the device to speed the repair in the

Ford 6.7L Power Stroke™ diesel engine without removing the cylinder head. Used properly, NICO™ will deliver excellent results and provide years

of reliable cost-effective repairs for you and your operation. 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 on engine side set for repair with the optional ProMAXX® PowerPull™ fuel injector PowerLift™ and/or

PowerHammer™ kit (see enclosed). Remove the valve cover and only those corresponding valve train components necessary to gain access to

the broken injector hold-down bolt. Cover/protect all open cylinder head cavities from cutting debris and remove any remaining portion of the

fastener that protrudes above the surface of the cylinder head so it is flush with the head. Remove any remaining debris on the cylinder head and

thoroughly clean the injector passage hole with an appropriate solvent prior to mounting the NICO ProPlate™ Assembly. Once cleaned, insert

the ProPlate™ nylon flange side down as shown below, (ProMAXX® logo down for LEFT side, ProMAXX® logo up for RIGHT side) into the injector

passage of the cylinder head carefully slipping the NICO™ assembly between two exhaust valves as shown below.

Using a 9/16” boxed wrench or deep socket and hand operated ratchet (do not use an electric or air powered ratchet or damage to the NICO™

expandable flange will result) and tighten the chrome hex nut (PHX375) until the ProPlate™ is securely anchored in the cylinder head so it

does not move. Once anchored, turn one-quarter to one-half additional. Insert ProBushing™ PPB2125 into the NICO™ assembly ™ until it seats

into the ProPlate™. Check the depth of an open injector hold down bolt hole and mark your tooling bit accordingly to eliminate damage the

cylinder head. Measure 2.00 inches from the tip of the ProMAXX® tooling drill bit up the shank and mark the dimension with a line and/or wrap

the tooling bit with tape to ensure proper clearance and avoid damage to the cylinder head. The line/tape will act as a visible depth stop for

this operation. Once set, select the included ProDrill™ SPJC125 machine tooling bit and insert it into a 3/8” capacity air or electric drill. Open

the cap on the ProLube™ PPL001 machine tap and cutting fluid and insert the small tooling bit in through the cap and gasket and retract. The

bottle is designed to deliver the right amount of oil necessary for the operation. For larger tooling and subsequent machining, place just one

drop on the end of the ProDrill™ and ProBushing™ and repeat as necessary. AVOID PENETRATING OIL/SPRAY. Insert the SPJC125 machine

tooling into the bushing first by manually turning your drill chuck with the mounted tooling bit by hand until the tooling drill rests on top of

the damaged bolt. Before drilling continuously, CRITICAL – turn/toggle/bump your drill on and off five to six one-second intervals applying

light pressure on the drill. This process will create a divot that will keep the tooling drill bit from walking, maintain precise alignment, and

allow the cutting edge to fully engage in the cutting surface. This will provide far more effective cutting action, precision, and prolong bit life.

Once complete, begin drilling continuously and regulate drilling speed to approximately 300 RPM or damage to the tooling bit may result.

Remove and replace the SPJC125 machine tooling bit with the SPJC188 bit, the PPB2125N ProBushing™ with the PPB2188O ProBushing™, and

repeat the process above. Repeat the steps once again utilizing the PPB2266O ProBushing™ and SPJC266 ProDrill™ tooling using a slower

RPM of approximately 150-250 for the largest bit. Once drilling is complete, clear all debris once again to ensure the surface is clean of all

debris. Lastly, insert the final PPB2320O ProBushing™ and using a 3/8” drive tap holder or tap handle attach to the ProTap™ PPT008 precision

machine tooling tap included. Add two drops of ProMAXX® ProLube™ drill and tapping fluid to two opposing flutes of the tap. Insert the

ProTap™ PPT008 into the bushing slowly turning the tap until it rest on the head and slowly by hand turn clockwise, then counterclockwise,

1/4 turn at a time, stopping frequently and using forced air via blow gun, send compressed air down two opposing flutes of the tap to clear

debris. Repeat this process frequently and carefully until the tap stops cutting. DO NOT OVER-TORQUE TAP. To prolong tap life, remove and

clean debris from tap and bushing when finished. Once complete, remove the ProPlate™ from the cylinder head by loosening the chrome hex

nut until is spins freely. It may be necessary to lightly tap the top of the ProArbor™ with a plastic faced hammer to unlock it from the cylinder

head. In the unlikely event a tap is fractured, visit www.promaxxtool.com and purchase the ProTap™ extractor kit. For technical support, visit

www.promaxxtool.com, or call 724-941-0941.

ProMAXX® tooling included in your kit are precision-machine production grade quality made in the USA and engineered as a complete system

to ensure complete success and repair of the cylinder head without removal. It is specifically engineered to controlled precision tolerance of

(+) .000”/ (-).001” to ensure accurate and repeatable results using your new NICO™ tool. SPECIFY PROMAXX® GENUINE REPLACEMENT PARTS

AND TOOLING FOR OPTIMUM PERFORMANCE AND EXTENDED WARRANTY COVERAGE.

SAFETY PROCEDURE: ALWAYS USE APPROPRIATE SAFETY EQUIPMENT

INCLUDING OSHA APPROVED SAFETY GLASSES/GOGGLE AND PROTECTIVE

GLOVES WHILE USING THIS DEVICE AND PERFORMING THIS OPERATION

VIEW NICO USER GUIDE

Fuel Injector Puller User Guide Info

POWERPULL INSTRUCTIONS

NEED HELP? WE LOVE HELPING OUR CUSTOMERS!

DIAL 724-941-0941 We are only successful when you are.

Thank you for investing in the ProMAXX® PowerPull™ series fuel injector removal tool for the Ford® 6.7L Power Stroke™ diesel engine! This device eliminates the unnecessary step of bolting the tool to and from the cylinder head. Precision machined from hardened steel to eliminate creep, bending, cracking, or failure of the tool.

PowerPull™ Lift Kit Remove fuel line(s) and connections from the fuel injector(s) as well as the injector hold-down bolt and fork. Slip the ProLift™ knurled pad into the valve cover where the fuel injector hold-down passes through. Place the PowerLift™ assembly fork under the fuel injector and push it toward the injector until it seats and aligns with the PowerPad indent. Using a 3/8” drive ratchet with hex socket attached, turn clockwise until the injector lifts free.

PowerHammer Kit (Consists of Hammer, Slide, Acorn Nut, Impact Washer, ProAdapter™) The ProAdapter™ portion of the PowerHammer assembly shown above is designed to be used by itself to remove the injector. Simply slip a small pry bar under the ridge of the ProAdapter™ and apply leverage to remove as shown in the middle photo to the right. For a difficult injector removal, attach the ProHammer slide assembly to the ProAdapter™ as shown in the photo to the right and use quick action to remove the injector. For even more challenging injector removal, utilize both LIFT to add tension, and ProHammer to shock the injector free.

SAFETY PROCEDURE: ALWAYS USE APPROPRIATE SAFETY EQUIPMENT INCLUDING OSHA APPROVED SAFETY GLASSES/GOGGLES AND PROTECTIVE GLOVES WHILE USING THIS DEVICE AND PERFORMING THIS OPERATION.

PowerPull User Guide PDF

View Instructional Videos: Fixing Broken Fuel Injector Bolts & Pulling 6.7L Fuel Injectors