Triumf 24952 Bedienungsanleitung
24952 Broken stud M8 remover kit with press function, version Nr.1- y.2016
Security precautions
To understand the activities of the instrument is required in advance to read these instructions!
- Carefully and in the right order, please read this manual before setting - up the device
- At work, always follow the data in the instructions / maintenance manual manufacturer for
current information and steps in the right order
- The instructions for use and recommended tools in this set are as a guideline and it is no
guarantee for success
- This set contains special products, which was several times successfully tested and used
successfully. It is necessary to pay attention to the accuracy of compliance with the order of
the steps
- The device must only be used professionally
Set 24952 contains instruction manual + detailing photo documents.
Set is packed in EVA foam in plastic case.
All part are available separately.
Part list
Item nr.
Description
Q.
Triumf item
1
Short rail nr1 with arch
1
34910
2
Short rail nr2, straight
1
34911
3
Longitudinal rails with centering holes
2
34904
4
Centering tip D8mm, (yellow zinc)
1
34917
5
Centering tip D8mm, deep (blue zinc)
1
34919
6
Drilling tip D9mm, (green)
1
34918
7
Extra long tap M10 x 1,0 length 200mm
1
26399
8
Centering guide for tap 26399
1
35260
9
Long HSS twist drill Ø 9,0mm cobalt 5%, fully ground
4
12849
10
Short HSS twist drill Ø 9,0mm cobalt 5%, fully ground
1
35322
11
Spare stud Fiat Ducato 3.0
4
35069
12
Glue for threads 5 ml
1
5259
13
Inbus " T " handle keys, both sides, size 2340 2,5x150
1
35279
14
Inbus " T " handle keys, both sides, size 2340 5x150
1
35280
15
Combination spanner 22mm, DIN 3113
1
1110
16
Spring washer 8,2 Zn, DIN 7980
4
35221
17
Washer 8 DIN125 Zn 8.4
4
31096
18
Nut hex M8 Zn DIN 934
4
32018
19
Main drilling unit with press function
1
35259
20
Tap wrench
1
23953
21
Plastic case
1
35290
22
EVA foam
1
35281
Picture1. Set 24952 –Part list
Problem localization:
Set of special tools is suitable
for light commercial vehicle
with engine 3,0l:
Engine code F1CE-3,0l in:
Fiat Ducato
Iveco Daily, Massif
Peugeot Boxer
Citroën Jumper (Euro 3, 4 & 5)
Mitsubishi Fuso Canter
Diesel injectors of the engines mentioned above are fixed by bolt M8. The bolts of all
injectors are situated in the camshaft cover recess, which is on the right end in the cover
camshafts with drainage groove. Drainage groove serves the water remowing which has
flowed through a leak between the windshield and the hood. This technically imperfect
solution to drain water causes water retention around the injectors and injector bolts which
penetrates and settles between the steel bolt and the head of the cast, where bolt formed solid
precipitate in the height of 22 mm. It cannot be chemically removed; it can be removed by
manually linkages breaking.
Picture 2. Dismantled cylinder head of engine Fiat Ducato HPi 3.0l
Picture 3. Cylinder head cross cutting view Fiat Ducato HPi 3.0l
Said in other words. Thread is a cylinder head around 20 in length (28 mm as shown
picturenr.3) and sediment - corroded joint 32 mm.
Such a large rust resistor cannot be overcome to release with 13 mm sockets and in most cases
tear off the head bolts in all 4 injector holders also the new vehicles.
The follow drilling out process is very complicated because the bolt is made by rolling the
compacted material especially at the point of the thread, between the beginning and the bolt
body. (Bolt hardness 10.8).
Inproper free drilling out done by hands in wrong speed without cooling and without
removing chips also with inaccuracies drill heads almost always results in imprecise drilling
and break the cylinder head wall. So it should not fully drill out of original thread or drilling
the water canal, which is located just below the end of the bolt.
Drilling out broken stud takes three hours also for manualy operation skillfully workers, (for
all four injectors 12 hours).
Mechanics also make this operation simpler. Work can be fastening by drilling stud the
injector after removing the cylinder head. It brings with additional time and costly action such
as draining coolant, replace head gasket and others.
When stud is drilled out, the tolerance goes away. Injector retaining bolt has original thread
M8x1,25. It is insufficient and therefore it is necessary to stocking threaded inserts "Helicoil"
(spring system). Mechanics facilitate their work and incorrectly insert coil into the camshaft
cover because of elaborateness and complexity of the operation. But it is wrong.
Solution
The solution to this issue is The drill out device - manufactured by Triumf with order number
24952.
Picture 4. Injector fixing bolt Fiat Ducato HPi 3.0l
Picture 5. Body of drilling out mechanism from set 24952
Despite the time consumption associated with dismantling workspace is time saving as well as
a guaranteed result of the work. The working comfort is unparalleled advantage with the time
required for removal of the above-mentioned parts.
Before installation of drilling mechanism is necessary to dismantle the injector in order to
properly drilling block centering with respect to the exact positioning or centering and drilling
tip for broken stud M8.
The process of removing the original stud including new stud installing is a matter of minutes
(10-15 minutes).
Tool construction:
The base of stud drilling out set are 4 rails that create the support frame with pre-drilled holes
on the localization longitudinal rails. Then you install drilling out mechanism where the final
position of drilling out block can tune / finely set the centering flap. It allows removal and
insertion of the drilling unit or use correction tap without re-setting the individual parameters.
Workers can continue his work where was interrupted and begin there. During the work it can
be easily lubricated, removing chips and control of the drill tip.
Downforce actually in drilling out is balanced due to the leveraging mechanism. Drill
machine is still at the same angle thanks to centering sleeves.
Position of drill machine is aligned with guide sleeves. Force transferring also in higher
pressure is smooth, given the installed bearings.
Picture 6. Detail photo injector retaining bolt M8x1,25
If injector is dismantled, we are recommended to blind injector holes with special tool - order
No. 23542 (blind hole injectors cap Ø10mm, shaft 7mm, 6x plus insertion tool - not included
in the kit) and the remaining holes, hoses, tubes sealed and cover with cloth.
All visible engine parts that could prevent proper installation and use of the products must be
removed from the work area.
The following photo documentation shows removed and dismantled cylinder head and
cylinder head prepared for mounting of drilling out mechanism for stud removing and
remowing the most important parts that could mislead at work
Picture 7. Before installation drilling out block must be removed engine components such as fuel
lines, electrical wires, air ducts and others.
Picture 8. Injector hole blinding tool for Fiat Hpi 3.0l
Picture 9. On the left is dismantled cylinder head of Fiat Hpi 3.0l, right dismantled engine parts needed
for installation drilling out mechanism from set 24952
Installation procedure of drilling mechanism
1 Support rails installation for drilling mechanism
TIP: Rails are selfcentering. Rail centering is not necessary, since the holes are precision pre-
driller.
To make faster and easy to install drilling mechanism are all screws with inbus head 5mm.
Rails contain also predrilled holes M8.
All rails are designed to not cause any confusion to change by each other. This way you do
not use force for proper installation and therefore do not force or increased their strength in
the assembly. Therefore, these components made of lightweight aluminum profiles.
1.1 Dismantle by T handle 5 mm Allen key (# 12), two original screws on the left side of the
cylinder head (see detail red circles to indicate the location of the screws).
Picture: Cylinder head of engine Fiat 3.0 diesel
1.2 Fit rail nr.1 on place of two removed scres. This rail is in its middle part specially shaped
to provide space for drilling out of broken stud on the first cylinder. C type of rail towards the
Picture 10. Screw position, neccesary remove for installation rail nr.1
Picture 11. Remove 2 screws using T handle allen key nr.14 and fittinng rail nr.1
inside of the cylinder head. Place rail nr.1 in screwing by original bolts using T Allen key size
5 mm (No.14) to the rail.
1.3 Fit the rail nr. 2 on the opposite side (right side of the cylinder head near the cylinder No.
4). Rail nr. 2 is placed parallel to the rail nr.1, that is in its upright position. This rail, in
contrast to rail No. 1 has no special molding shape. Correctness of this rail is given / provided
rounded corners moldings facing outwards from the cylinder head. For fixing rail No.2 use
screws that are part of this bar and are therefore part of the set 24952. set screws are screwed
firmly by T Allen key 5mm (No. 14).
Note: Bolts of rails No. 1,2,3 need to be tightened by hand. Accompanied T Allen key is fully
sufficient to tighten these screws.
1.4 Fix rear rail (one of a pair of rails no. 3) with two recesses in the middle of the ends of the
seats already mounted rails No.1 and No.2. Rail directs towards the protrusion in the engine
cam housing. The rails are elongated threaded holes M8, which will subsequently be used to
adjust the position of drilling mechanism for each injector to mount the base plate of drilling
block.
Correctness of this rail is given by rounded corners at the rear. This rail can not be fitted on
the contrary. Direction is done the sustainability of logs in the rail with respect to the shape of
the cam housing. Install rail by two screws, which are part of the rail. Tighten the screws with
T Allen. key 5 mm (No. 14).
1.5 Install the last - the front rail (second bar of the pair of long rails, the number 3). This rail
does not contain any recesses and notches. The accuracy is determined by the round edges
towards the outside of the mounted frame, consisting of 4 rails. This frame is used for
Picture 11. Installation of rail nr.2 using by screws with 5mm allen head.. (rails already contain screws)
Picture 12. Mountings the rear rail No. 3 on the already placing rail 1 and the nr2.
installation drilling out mechanism. All rails must fit properly in their recesses and outer
corners of the support frame of the drilling mechanism. It must be withheld roundly. Fit the
last rail using two screws (also part of this rail).
2 Prepare of broken stud and choose the correct centering tip
2.1 After the mounting rails is necessary to prepare a stud. Before installation of drilling
equipment must be stud cleaned at least slightly from corrosion or remove the mini angle
grinder or shaped visibly deformed part by slice of saw (but this is rare). The important thing
is to allow fit centering tip the short / long one (depending on the length of the pins) for the
protruding stud . Both tips are with a diameter of 8 mm.
2.2 If stud was broken in right high level and sufficiently protrudes above the cam cover is
sufficient for only a short tip (# 4) if stud is below the cover cams use the extended tip of the
cranked stud (6).
Before installation of drilling mechanism is necessary to dismantle the injector in order to
properly drilling block centering with respect to the exact positioning or centering and drilling
tip for broken stud M8.
Picture 13. Installation the front rail (one of a pair of rails No. 3) and then complet mounting support
frame for mounting drilling mechanism.
Broken stud is neccesary resurface, straighten the edges in the case stud is bent so to pass a
neck centering tip 8mm - tip # 4 or # 6, due to possibility of variant broken stud.
Tips dividing:
- yellow centering tip for broken stud (nr.4). 8mm –yellow zinc coating.
- blue centering tip for deep broken stud (nr.5). 8mm –blue zinc coating.
- green tip 9mm (nr.6)
Picture 14. Injector retaining broken stud Fiat Hpi 3,0l
Picture 15. Tip Installation of the drilling mechanism. Screw the tip using by combination spanner 22mm
(No.15).
Picture 16.Tips diversification
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