Pichler 60417300 User manual
Universal Reamer and Pipe Brush Set
23 pcs.
60417300
Manual
Page 2 of 14
Page 3 of 14
Introduction
In diesel engines a build-up of combustion residues or carbonisation occurs very frequently around the
element of the glow plug. Sometimes this can causes the element to stick in the cylinder head, which in turn
leads to a heat build-up.
Contamination can enter the glow plug hole which also leads to problems such as corrosion, especially
around the thread of the glow plug as well as the rest of the hole.
Why should the glow plug hole be cleaned in the cylinder head?
During the installation of a new glow plug, carbon remains in the bottom part of the glow plug hole, which
causes the element to break, this then prevents it from being screwed in.
The glow plug shaft should be cleaned when replacing the glow plugs, otherwise carbon deposits cause an
accumulated heat build-up in the new glow plug, which leads to overheating.
It is also important to regain an optimal seal. This is done by reaming the sealing cone with an
appropriate reamer.
Contents
1.
Cleaning the glow plug shaft with a pipe brush ..........................................................................................6
2.
Cleaning and correcting the sealing seat angle in the cylinder head using a reamer................................8
Overview and composition of the various reamers........................................................................................10
3. Cleaning and checking....................................................................................................................................12
Recommended accessories................................................................................................................................13
Page 4 of 14
Contents:
Nr. P/N Description 60417300
1 6049031 Steel Wire Pipe Brush Ø11,0mm 1
2 9049026 Brass Wire Shouldered Pipe Brush Ø4 /Ø6 /Ø9mm 1
3 6049029 Steel Wire Pipe Brush Ø8,5mm 1
4 6049027 Steel Wire Pipe Brush Ø7,0mm 1
5 6049026 Steel Wire Pipe Brush Ø6,5mm 1
6 6049025 Steel Wire Pipe Brush Ø5,3mm 1
7 6049024 Steel Wire Pipe Brush Ø4,7mm 1
8 60417104 Universal Glow Plug Shaft Reamer 120° 1
9 60416228 Glow Plug Shaft Reamer M8x1 - 120° 1
10 1512042 Allen Key 2mm 1
11 6041628 Glow Plug Shaft Reamer M8x1/M9x1 - 90° 1
12 4024030 Angle Gauge 60° - 90° - 120° 1
13 6041729 Glow Plug Shaft Reamer M10x1/M10x1,25 - 60° 1
14 60417028 Glow Plug Shaft Reamer M10x1/M10x1,25 - 90° 1
15 6041618 Glow Plug Shaft Reamer M12x1,25 - 60° 1
16 6041617 Screw In Guide M12x1,25 1
17 60417027 Screw In Guide M10x1 1
18 60416027 Screw In Guide M9x1 1
19 60417026 Screw In Guide M10x1,25 1
20 6041627 Screw In Guide M8x1 1
21 60416166 Actuator With Square Holder 4,3mm 1
22 6041626 Actuator With Square Holder 3,4mm 1
Page 5 of 14
Always refer to the OEM manufacturer’s instructions and service manuals for the
latest data and to maintain the correct sequence.
These work instructions and the recommended tools shown are meant to serve as
aides only and are by no means a guarantee for certain results.
This tool kit is a special collection and it has been tested and used successfully on
several occasions.
It is of the utmost importance to maintain the correct procedure as per the
instructions.
The use of the tools should only be carried out by qualified personnel.
Pictograms and their meaning:
Special caution or attention
Hint or recommendation
Wear safety goggles
Right
Wrong
Page 6 of 14
1.
Cleaning the glow plug shaft with a pipe brush
1.1. Clean the removed glow plug with suitable equipment (this is not needed with a new part).
1.2. Measure the diameter of the heating element and the glow plug.
E
lement
Shaft
Page 7 of 14
1.3. Select based on the previously determined diameter of the element the pipe brush with the same or next
larger diameter.
Thread Pipe Brush P/N
M8
M9 Steel Wire Pipe Brush Ø4,7 6049024
M10 Steel Wire Pipe Brush Ø5,3 6049025
M12 Steel Wire Pipe Brush Ø6,5 6049026
1.4. Select based on the previously measured diameter of the shaft of the glowplug the pipe brush with the same
or next larger diameter.
Thread Pipe Brush P/N
M8
M9 Steel Wire Pipe Brush Ø7,0 049027
M10 Steel Wire Pipe Brush Ø8,5 6049029
M12 Steel Wire Pipe Brush Ø11 6049031
Shouldered Pipe Brush
Cross section of the cylinder head
Cross section of the cylinder head
With some engine manufacturers cleaning is only permitted
with a brass brush, so that a gentler cleaning is achieved.
Brass Wire Shouldered Pipe Brush Ø4 /Ø6 /Ø9mm
9049026
Cross section of the cylinder head
Page 8 of 14
1.5. Clean the glow plug hole in the cylinder head from carbon deposits with a suitable pipe brush and remove the
loosened deposits with a suction device.
2. Cleaning and correcting the sealing seat angle in the cylinder head
using a reamer.
2.1. Determine the thread size using callipers and a thread gauge.
A) Determining the thread diameter. B) Determining the thread pitch.
Cross section of the cylinder head
A
B
for example:
M10
x
1.25
Page 9 of 14
2.2. Determine on the glow plug the sealing seat angle with the angle gauge 4024030.
Angle Gauge (60°, 90° & 120°)
4024030
Use the angle gauge (60, 90, 120) to find
the exact glow plug sealing seat angle
Angle does not match
Example: glow plug with sealing seat angle 60°
Angle does match
Page 10 of 14
Overview and composition of the various reamers
2.3. Using this table, select the correct reamer components.
Composition
Individual parts
Reamers
Sealing seat angle
of the reamer Guide Actuator
M8x1 / 90°
6041625
90°
6041628
M8x1
6041627 No. 1
6041626
M8x1 / 120°
60416225
120°
60416228
M8x1
6041627 No. 1
6041626
M9x1 / 90°
60416215
90°
6041628
M9x1
60416027 No. 1
6041626
M10x1 / 60°
6041725
60°
6041729
M10x1
60417027 No. 2
60416166
M10x1 / 90°
60417025
90°
60417028
M10x1
60417027 No. 1
6041626
M10x1.25 / 60°
60417225
60°
6041729
M10x1.25
60417026 No. 2
60416166
M10x1.25 / 90°
60417029
90°
60417028
M10x1.25
60417026 No. 1
6041626
M10x1 / 60°
M10x1.25 / 60°
6041715
60°
6041714
Guided by the
reamer shaft
No. 2
60416166
M10x1 / 120°
M10x1.25 / 120°
60417105
120°
60417104
Guided by the
reamer shaft
No. 2
60416166
M12x1.25 / 60°
6041615
60°
6041618
M12x1.25
6041617 No. 2
60416166
Page 11 of 14
Coat the reamer with
grease (e.g. 60200035)
to bind the removed
material.
2.4. Slide the selected guide to the start of the reamer. Place the reamer with the guide beside the glow plug,
making sure the threads line up.
2.5. Screw in the guide in the glow plug shaft first until it stops. Then back off half a turn and carefully slide the
reamer into the glow plug shaft.
2.6. Place the actuator on the square of the reamer and clamp it.
X
The length "X" may never exceed the distance "A" other wise
the reamer is clamped in the glow plug shaft when screwing in
the guide!
Reamer Guide
Distance A
Page 12 of 14
Using compressed air or a vacuum cleaner remove any deposits.
Visually check (e.g. with a videoscope) the cleaned glow plug
hole for cleansiness and if necessary repeat the cleaning
process from 2.4.
2.7. Carefully, with minimal pressure rotate clockwise only and clean the
sealing cone from carbon deposits
If space is limited can the actuator be e tended with an e tension and a socket 10.
3. Cleaning and checking
After completion of the cleaning, remove the actuator from the
reamer and unscrew the guide with a socket and carefully pull the
shouldered reamer out of the hole.
Rotate clockwise only and
apply only minimal pressure!
Cross section of the cylinder head
Cross section of the cylinder head
Page 13 of 14
Recommended accessories
Videoscope “EXCLUSIVE”
9078050
Videoscope Mount
9078054
Calliper
4025000
Flexible Lamp “BAL”
40103000
Thread Gauge
4024000
Glow Plug Cone Seat Angle Gauge
60°/90°/120° (3 in 1)
4024030
AUSTRIA
+43 512 344552
PICHLER Werkzeug GmbH & CoKG
Pacherstrasse 20
A-6023 Innsbruck
GERMANY
+49 8821 6869780
PICHLER Werkzeug GmbH
Zugspitzstrasse 33
D-82467 Garmisch-Partenkirchen
SWITZERLAND
+41 61 981 33 55
PICHLER Werkzeug AG
Rünenbergerstrasse 31
CH-4460 Gelterkinden
FRANCE
pichler@pichler.fr
+33 389 551 596
PICHLER Outillage Sàrl
19a, rue de Reiningue
F-68310 Wittelsheim
BELGIUM
belgique@pichler.fr
+32 495 400810
PICHLER Outillage BVBA
Industrieweg 45
B-8800 Roeselare
GREAT BRITAIN & IRELAND
+44 1335 360759
PICHLER TOOLS LTD
Ednaston Business Centre
Hollington Lane, Ednaston
Ashbourne
DE6 3AE
www.pichler-werkzeug.com ·www.pichler-tools.com ·www.pichler-outillage.com
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