ISUZU 5.2L 4HK1-TC Diesel Exhaust Manifold Broken Bolt Repair Kit - Anthony

What is the ISUZU 5.2L DIESEL Exhaust Manifold Repair Kit?

The ISUZU 5.2L DIESEL Exhaust Manifold Broken Bolt Stud Repair Kit, along with every other USA-made ProMAXX Tool solution, greatly reduces repair times, allowing professional vehicle technicians and skilled mechanics to quickly make the fix and move on to other jobs. The kit is easy to use, and it comes with instructions and schematics that show the best ways to mount the guide plate and use the included drill bit tooling to get at every broken bolt on the manifold.

Make the Broken Bolt Repair Fast…ProMAXX Fast!

With a focus on book time saved, return on investment, and increased productivity, experienced technicians and mechanically adept individuals who follow the provided instructions can use these kits to make the fractured stud repair in approximately 15 minutes per bolt*. A professional-grade drive ratchet is required to make the repair. The guide plate bolts to the top or bottom of the cylinder head, providing unrivaled accuracy and precision.

*Repair times may vary depending on the location of the broken bolt, whether a previous extraction attempt such as welding has occurred, if a previous repair resulted in a broken extractor or bit and the number of broken bolts. In repairs with multiple broken bolts, ProMAXX Tool recommends purchasing additional drill bits. In the case of repairs involving broken bits or extractors, a ProMAXX Tool Broken Extractor Repair Kit is recommended.

How does the ISUZU 5.2L DIESEL Broken Bolt Repair Kit work?

Like all ProMAXX Tool broken bolt repair kits, the ISUZU 5.2L DIESEL Engine Exhaust Manifold Broken Bolt Stud Repair Kit stands out for its exclusive screw-in bushings and proprietary mating angles, which ensure perfect alignment of the ProPlate jig with the cylinder head. The ProPlate can be bolted in any position with included precision fasteners, providing unparalleled repeatable and predictable results. This level of accuracy and precision sets the kit apart from other products on the market, which rely on inexpensive clamps or loose slip-fit bushings. The accuracy allows the user to drill dead-center on the bolt hole. For previous repair attempts or botched repairs, the ProKit’s larger plate holes provide the use of a thread repair kit that includes bushings, bits, and black-oxide coated threaded inserts to restore the cylinder head to factory condition.

Premium Machine-Shop Grade Drill Bit Tooling Included

ProMAXX Tool’s USA-made machine-shop-grade tooling bits are ground at 135° cutting angle (lip) with a split point. Flat ground bits cut slower and are long lasting but less accurate and will walk while drilling. Split point ground bits will stay on center to reduce walking because they have four cutting edges and distribute loads better. They work well on curved shapes and alloy and stainless steels because it creates smaller chips to minimize clogging holes and breaking bits. To prevent drill bit breakage, closely follow the instructions in the Exhaust Manifold Repair Kit User Guide.

How to Fix a Broken Exhaust Manifold Bolt Using the ISUZU 5.2L DIESEL Stud Repair Kit

The steps to use the ISUZU 5.2L DIESEL Repair Kit are detailed in the Exhaust Manifold Repair (EMR) manual. The manual provides a step-by-step guide on how to mount the ProPlate to the cylinder head, how to insert the ProBushing and ProDrill into the ProPlate, how to set the cutting edge, and how to extract the remnant or go Extractorless™ and drill the bolt out entirely. In the case of extraction or tap failure, ProMAXX Tool provides free 24/7 technical support at 724-941-0941.

Exhaust Manifold Bolt Repair ISUZU 5.2L DIESEL Key Success Drivers

• Fastest — Interchangeable bushings with fasteners and Extractorless™ capability.
• Easiest — 1/3 of the size of other drill guides on the market, increasing maneuverability and allowing for "On The Truck" repairs.
• Smallest — easily fits behind the shock tower.
• Most Precise — engineered .001” accuracy, .0001” dead flat.
• Versatile — Unique CNC machined thread repair kit available as well.
• Patented, Manufactured and assembled ENTIRELY IN THE U.S.A. by American craftsman with American made materials

Isuzu 4HK1-TC 5.2L Diesel User Info

Anthony - Exhaust Manifold Repaird

• Mount the ProPlate™ to the cylinder head using the included ProFast PPF008375 or PPF008500 precision fasteners according to the included cylinder head schematic. Torque to a minimum of 20 FT-LBS.
• Insert the ProBushing™ and corresponding ProDrill™ machine grade tooling bit into an air-powered angled style drill and use the drill depth gauge machined into the ProPlate™ to set the proper depth of the bit and mark the bit if necessary. Apply one drop of the ProLube™ PPL001 drilling & tapping cutting fluid. AVOID PENETRATING OIL/SPRAY OR OTHER LUBRICANTS.
• Insert the mounted ProDrill™ into the included ProBushing™ mounted in the ProPlate™ first by slowly and manually turning the chuck until the ProDrill™ slips into the bushing and contacts the surface of the damaged stud. This will ensure the cutting edge is not damaged. Important step to avoid drill bit breakage. While applying light pressure, activate your drill both on and off five times (ten times if utilizing an air ratchet) in one-second intervals. This is the MOST CRITICAL step of this repair as it facilitates precise alignment by creating a “seat” for the tooling bit to stay on center and not follow the angular broken surface of the stud. Moreover, this step allows the surface of the stud to conform to the cutting edge of the bit distributing the load evenly across the entire cutting edge of the bit providing for cutting extremely hard surfaces and extending cutting tool life.
• After this initial start, drill continuously running your drill at the proper RPM (see below) and while the bit is turning, extract the bit in and out of the damaged stud while maintaining it in the bushing to “clean” or “excavate” cutting debris from the stud. Repeat this step progressively exerting more pressure until your drill reaches the maximum depth.
• Remove the ProPlate™ and IF extracting the remnant, place the optional ProCutter PPC007A in your drill and toggle the drill on and off five times to remove the burr and clean the tapped hole. Place a mark approximately ¼” from the end of the optional ProTractor. Tap the ProTractor™ in to the depth of the line. DO NOT INSERT THE PROTRACTOR ANY FURTHER THAN AS INSTRUCTED ABOVE. Place the included slip-nut over the ProTractor™ and slide it up against the cylinder head. While holding the opposite end of the ProTractor™ and using a high-quality calibrated torque wrench, slowly and carefully apply torque, first in the clockwise direction, and then in the counter-clockwise direction to loosen the damaged stud. Repeat this motion several times by NOT EXCEEDING 75 IN-LBS OF TORQUE FOR THE PPT125 OR 150 IN-LBS FOR THE PPT188. If the damaged stud fails to release, STOP and remove the ProTractor™.

In more challenging cases, ProMAXX® recommends using the larger optional ProDrill™ (standard in some ProKits) and corresponding ProBushing™ to prepare in chasing/tapping threads to restore them to factory specifications. Repeat drilling instructons above for EVERY step. In the unlikely event an extractor fails, visit www.promaxxtool.com and search extractor repair kit. You may also contact technical support at 724-941-0941 for recommendations and procedures.

NOTE: ProMAXX® does not recommend tapered left-handed screw extractors as they have the potential to deform the remnant in the cylinder head increasing complexity of extraction. In addition, these extractors cannot be turned clockwise to unlock the damaged remnant. Approximate tooling cutting speeds (Under load): MIN: SSSC125@500 RPM, SSSC188/PLT188@300, SSSC270/ PLT270@250.

NOTE: Some air ratchets may not generate at sufficient RPM under load to be effective. SEE ProMAXX® ProRatchet PPR5260 or PowerDrill™ PPD2800 at www.promaxxtool.com for optimum efficiency and maximum productivity.

PROMAXX™ machine grade tooling is specially engineered to close tolerances of (+) .000” and (-) .001” and ground straight to ensure accurate and repeatable results in using your new device. Specify PROMAXX® genuine replacement parts and tooling for optimum performance and extended warranty coverage. Always use appropriate OSHA-approved safety glasses/goggles and protective gloves while using this device and performing this operation.

Anthony User Guide PDF