- AVSpare Products: All
Introduction
European Union Compliant, CE Marked
Important Safety Information
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Think Safety | |
Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.
Improper operation, lubrication, maintenance, or repair of this product can be dangerous and could result in injury or death.
Do not operate or perform any lubrication, maintenance, or repair on this product until you have read and understood the operation, lubrication, maintenance, and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as "DANGER","WARNING", or "CAUTION". The Safety Alert "WARNING" label is shown below.
A non-exhaustive list of operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.
AVSpare cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method, or operating technique that is not recommended by AVSpare is used, the operator must be sure that the procedures are safe. The operator must also be sure that the product will not be damaged or made unsafe by any unspecified procedures.
The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job.
When replacement parts are required for this product AVSpare recommends using AVSpare replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength, and material.
Literature Information
This manual contains safety information, operation instructions and maintenance information and should be stored with the tool group.
Some photographs or illustrations in this publication may show details that can be different from your service tool. Guards and covers might have been removed for illustrative purposes.
Continuing improvement and advancement of product design might have caused changes to your service tool, which are not included in this publication.
Whenever a question arises regarding your service tool or this publication, consult Dealer Service Tools (DST) for the latest available information.
Safety Section
The Safety Section lists basic safety precautions.
Read and understand the basic precautions listed in the Safety Section before operating or performing maintenance and repair on this service tool.
General Information Section
The General Information Section describes tooling functions and features. This section provides useful information on individual parts, additional tooling, and resources.
Operation Section
The Operation Section is a reference for the new operator and a refresher for the experienced operator.
Photographs and illustrations guide the operator through correct procedures for using the tool group.
Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the service tool and tool capabilities.
Maintenance Section
The Maintenance Section is a guide to tool inspection, cleaning, storage, and tool disposal.
Safety Section
Safety Icon Nomenclature
Personal Protection/Important Information
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Personal Protection/Important Information | |
Hazard Avoidance
| Crushing Hazard (foot) |
| Crushing Hazard (hand) |
| Pinch Point |
Personal injuries can occur as a result of using pressurized air. Maximum air pressure at the nozzle must be below 205 kPa (30 psi) for cleaning purposes. Wear protective clothing, protective glasses, and a protective face shield when using pressure air.
Additional Contact Information
For additional product support questions concerning this tool, contact the Dealer Service Tools Hotline at:
USA: 800-542-8665, Option 1
International: 1-309-578-7372
Note: Continuing improvement and advancement of product design can mean some photographs or illustrations in this publication will show details that are different from your service tool.
General Information Section
The 188-3922 Exhaust Stud and Bolt Removal Tool Group , when bolted to the cylinder head will accurately locate the center of the broken stud or bolt. This tool allows the broken bolt or stud to be drilled out without damaging the existing threads in the cylinder head. This tool group is similar to the 6V-9050 Exhaust Stud Removal Group except that it is designed to repair metric exhaust manifold bolts and studs. The 188-3922 can be used on cylinder heads of 3114, 3116, 3126, 3126B, 3176, 3176B, C-10, and C-12 Engines.
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188-3922 Exhaust Stud and Bolt Removal Tool Group. (Refer to table 1 for item identifications | |
| 188-3922 Exhaust Stud and Bolt Removal Tool Group | |||
| Item | Part No. | Description | Qty |
| 1 | 188-3914 | Drilling plate | 1 |
| 2 | 188-3915 | Bushing Lock Screw | 5 |
| 3 | 1U-8163 | Drill, 8.5mm | 1 |
| 4 | 1U-8133 | Drill, 2.5mm | 1 |
| 5 | 188-3923 | Bushing, 8.5mm (ID) | 1 |
| 6 | 188-3918 | Bushing, 2.5mm (ID) | 1 |
| 7 | 188-3916 | Bushing, 10mm (ID) | 4 |
| 8 | 8T-4186 | Bolt, M101.5 40 mm long | 4 |
| 9 | 6V-3072 | Storage Case | 1 |
| 10 | 188-3921 | Foam Insert | 1 |
| 11 | NEHS0787 | Tool Operating Manual | 1 |
| NEEG2895 | Decal | 1 | |
Fastener Removal Procedure
| Personal injury or death can result from misuse of electrical tools and equipment. To avoid shocks or other injuries, never use an ungrounded or inadequate extension cord, remove all jewelry, and avoid contact with electrical components. |
Avoid working in or standing in water and areas with high moisture content which could create paths of electrical conductivity.
Always use a grounded 3-wire extension cord with a 3-wire plug which is rated for at least a 15 A load, and protected by a suitable fuse or circuit breaker.
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- Use a suitable grinder to grind off any of the broken fastener protruding above the face of the exhaust manifold.
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- Read the markings on 188-3914 Plate (1) and orient it to the specific cylinder head being repaired. The engine type, stamped on the plate, should be readable in a normal way when the plate is correctly installed.
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3176B, C-10, and C-12 Engines. | |
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3114,3116, and 3126 Engines. | |
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3126B Engines | |
| NOTICE |
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Do not damage the exhaust manifold gasket surface while grinding the protruding portion of the fastener. |
- Select two or three hole locations and install 188-3915 Bushings (7) and 8T-4186 Bolt (8) to fasten the drilling plate to the cylinder head. In some cases, the exhaust stud and a nut can be used in place of the M10 bolts.
Note: Due to the large number of holes in the drilling plate, the holes are not marked for specific bolt locations and some adjacent studs must be removed to provide clearance for the plate. On 3126B cylinder heads, the small allen head plugs must be removed to allow the plate to sit flush on the cylinder head. If the plugs are removed, discard the O-rings and replace them with new O-rings.
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Install Plate (1) With Bushing (7) and Bolt (8) . | |
- Make sure the fastener being removed is centered in the hole of the drilling plate.
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Make Sure Fastener is Centered in Hole. | |
- Check the depth of the hole using an identical hole and mark 1U-8133 Drill Bit (6) to avoid drilling too deep.
| NOTICE |
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The exhaust manifold fasteners are taper lock studs. These studs normally do not have a large air space between the end of the stud and the bottom of the hole. It is important to check the depth of an adjacent hole to set the drill depth. Drilling too deep will cause cylinder head damage. |
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Check Depth of Adjacent Hole and Mark Depth on Drill Bit. | |
- Install 188-3918 Bushing (6) in the drilling plate and secure it with a 188-3915 Bushing Screw (2) .
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Install Drill Bushing (6) with Lock Screw (2) . | |
- Drill a pilot hole in the broken stud with 1U-8133 Drill Bit (4) .
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Drill Pilot Hole with Drill Bit (4) . | |
- Check the depth of the hole of an adjacent hole and mark 1U-8163 Drill Bit (3) to avoid drilling too deep.
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- Install 188-3923 Bushing (5) and bushing lock screw (2) .
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Install Drill Bushing (5) with Lock Screw (2) . | |
- Install 188-3923 Bushing (5) and bushing lock screw (2) .
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Drill Out Broken Fastener with Drill Bit (3) . | |
- Use a pick or other suitable device to remove any remaining metal chips.
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- Using a tap, recondition the threads.
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- Clean the threaded hole to remove all debris.
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