SW-Stahl GmbH
Tel. +49 (0) 2191 / 46438-0
Leverkuser Straße 65
Fax +49 (0) 2191 / 46438-40
D-42897 Remscheid
E-Mail: [email protected]
03671L
www.swstahl.de
BEDIENUNGSA
NLEITUNG
/
INSTRUCTION MA
NUA
L
SAFETY INSTRUCTIONS
Always wear safety goggles.
Make sure that the tool has been properly installed.
Do not over-tighten the spindle or apply excessive force as this may damage the tool.
Do not use an impact wrench to avoid damages to the spindle.
Grease the thread on the spindle before using the tool.
Check and, if necessary, replace any damaged tools.
Use caution when working on hot engines – risk of burns!
Use caution when working on running engines. Loose clothing, tools and other object can get caught
in rotating parts and, thus, cause severe personal injuries.
Remove the ignition key before you start your repair job to avoid unintentional starting of the engine.
These instructions are intended as an overview only and can by no means substitute a workshop
manual.
Always use car-specific repair manuals to look up information such as torque values,
disassembly/assembly instructions, etc.
APPLICATION
Drilling out broken-off glow plug and repair of the thread.
24. Remove all components as necessary.
25. Install the cover plate (
9
) with the original bolts on the intake manifold.
26. Make sure that the piston is in TDC position.
27. Remove the injector of the cylinder under repair.
28. Install the injector shaft compressed air adaptor (
10
) in the injector shaft. Caution: block the crankshaft
against rotation, connect the injector shaft compressed air adaptor (
10
) to the compressed air supply
and open the valve.
29. Use the suitable electrode screw extractor to shear off the electrical connection (electrode) by rotating
it in the direction of rotation.
30. Remove the broken-off center electrode and hexagon from the shaft.
31. Visually check the position where the rest of the center electrode has broken off:
§
Center electrode broken above at the connection; remove the remainders of the electrode with the
electrode screw extractor, continue with step 13.
§
Center electrode broken off inside the glow plug body; in this case the glow plug body can be
directly removed with a core drill, continue with step 13
§
Center electrode broken off in the middle; remove the remainders of the electrode with the reamer
(
11
), and continue with step 9.
32. Position guide sleeve (
15
) at its maximum depth inside the glow plug shaft.
33. Lubricate the reamer (
11
) and mill out the center electrode at a rotational speed of 500 rpm until the
limit stop at the end of the reamer comes to rest on the guide sleeve.
34. Exchange guide sleeve (
15
) against guide sleeve (
14
).
35. Oil the reamer (
11
) and again mill out the center electrode at a rotational speed of 500 rpm until the
limit stop at the end of the reamer again comes to rest on the guide sleeve.
36. Oil the drill (
6
), insert it into the guide sleeve (
14
) and exert a very light pressure while drilling a hole
into the glow plug at a rotational speed of 500 rpm. Note: remove swarf every now and then with
compressed air. (Caution: wear safety goggles). The working step will end with the collar of the drill
drive coming to rest on the edge of the sleeve.
37. Remove drill and guide sleeve and use compressed air to clean all swarf / foreign particles from the
glow plug shaft.
38. Oil the tap drill (
16
), clamp it into the tool holder (
1
) and by hand drill an approx. 5 mm deep thread
into the glow plug body.
39. Use the extraction tool (
12)
to screw the spindle into the prepared thread.
40. Open the valve on the injector shaft compressed air adaptor.
41. Now, the remainder of the glow plug can be pulled out by rotating the 19 mm hexagon part on the
extraction tool (12).
42. Position guide sleeve (
14
) at its maximum depth inside the glow plug shaft.
43. Wet the drill M10x1.0 (
8
) with alcohol and rethread the thread by hand; the working step will end with
the limit stop at the end of the drill coming to rest on the guide sleeve (
14
). During this working step
the injector shaft compressed air adaptor has to be connected to the compressed
