INSTRUCTIONS
Contents
1. ButLteTPrRooFDIESEL LOM INSTRUCTIONS CYLINDER HEAD TEST AND REPAIR KIT FORD 6 0L F SERIES amp E SERIES NEAL TECHNOLOGIES INC UPDATED 7 16 2015 2014 BULLET PROOF DIESEL CYLINDER HEAD TEST AND REPAIR KIT FORD 6 0L F SERIES amp E SERIES Problem A common pattern failure identified in the Ford 6 0L diesel is fuel in the cooling system Fuel in the cooling system is a result of a crack in the cylinder head s specifically forming in the injector bore in between the cooling and fuel systems Fuel contamination within the cooling system will result in fuel attacking the rubber hoses and O rings of the cooling system compromising their integrity Cure Bullet Proof Diesel has developed a method that fixes the problem at the source Bullet Proof Diesel developed a tool that fits directly into the injector bore that allows our cylinder head sealant to be directly injected at high pressure into the identified crack Benefits There are several major benefits to this cylinder head injector bore repair This repair is done without removing your cylinder heads This saves on down time labor and parts cost Another great benefit is the ability to perform this repair without needing a specialized shop or other specialized tools This repair can also be done by the at home mechanic who is trying to save a little time money and headache Overall this repair method allows you to effectively and efficiently repair cy2. 6000105 All F series All F series Ford OEM oil filter 1 6000049 All E series Ford OEM fuel filter 2 6000116 All E series EGR Cooler Gasket Set Complete 90100022 comes with intake manifold O ring o 8 aes Cylinder Head Test and Repair Kit BulletProofDiesel com
3. 8mm Plug Driver side Passenger side NOTE Removal of the starter may be required to reach the block plugs a Cylinder Head Test and Repair Kit BulletProofDiesel com 3 Following the Ford factory procedure for injector removal remove all 8 injectors 4 Clean and dry all injector bores NOTE DO NOT use fluids or solvents to clean We recommend using a dry shop towel Ps Cylinder Head Test and Repair Kit BulletProofDiesel com 5 Install rubber stoppers in the bottom of each injector bore on the passenger side 6 You must now reinstall all parts removed in the cooling system draining process This will allow you to pressurize the cooling system 6 Cylinder Head Test and Repair Kit BulletProofDiesel com 7 Using a cooling system pressure tester pressurize cooling system to 20psi MAX NOTE DO NOT over pressurize Damage or injury may occur NOTE If you do not have a cooling system pressure tester Bullet Proof Diesel offers them for sale with the kit Please note the tool pictured above is not the tool Bullet Proof Diesel sells Please refer to the following page for information on the optional tool you will receive ee Cylinder Head Test and Repair Kit BulletProofDiesel com 8 Using WD 40 fill the plugged injector bores to the top and check for bubbles to identify a cracked injector bore No bubbles present NOTE Cracks form on the exhaust manifold side of the injector bore 9 Smal
4. l cracks may be difficult to see Be patient and thorough 10 Once a crack or cracks are identified carefully clean up and dry out the WD 40 Er Cylinder Head Test and Repair Kit BulletProofDiesel com 11 Remove the rubber stoppers 12 Clean and dry injector bores thoroughly ensuring ALL foreign objects debris and contaminates are removed 13 Repeat steps 5 12 on the opposite cylinder head NOTE Surface and bore prep are CRITICAL Use new gloves to keep surfaces tools and work area clean 10 Cylinder Head Test and Repair Kit BulletProofDiesel com Stage 3 Preparing and Using Cylinder Head Tool for Repair 14 Prepare the repair tool for use a Lubricate the O ring with a light coat of clean engine oil or assembly lube b Using additional lubrication ensure the tool is lubricated all the way around to the back of the injector tool in the same manner as the O ring ee Cylinder Head Test and Repair Kit BulletProofDiesel com c While holding the injector tool in one hand slide the wedged portion open to expose the interior as shown Lightly lubricate this exposed area on each side of the tool d Once properly lubricated gently slide the wedged portion open and closed a few times to work the lubricant into the grooves ee Cylinder Head Test and Repair Kit BulletProofDiesel com e Index the OEM injector hold down clamp to the notch on the injector bore tool f Using a pape
5. linder head cracks without the traditional costs associated with head repairs NOTE Our studies have shown a high rate of success in repairs when done properly Please note there are several factors that could affect the outcome of this repair so please follow instructions very carefully We know this repair method has proven to be successful however repair results are NOT guaranteed O a Cylinder Head Test and Repair Kit BulletProofDiesel com CYLINDER HEAD TEST AND REPAIR KIT Stage 1 Verifying Fuel in the Cooling System 1 Verify that there is diesel fuel in the cooling system using the symptoms listed below a Looking inside your degas bottle is there visible fuel floating in the coolant b Can you smell fuel in degas bottle c Is the degas bottle cap swollen d Are the coolant hoses spongy m Degas bottle Degas bottle cap Qe Coolant hose NOTE Engine oil or a chocolate milk like substance in the degas bottle is likely a different issue This will most likely require the replacement of the engine oil cooler If you have oil in your coolant please call us before you proceed i Cylinder Head Test and Repair Kit BulletProofDiesel com Stage 2 Verifying Cracks in the Heads 2 If you verify the previous symptoms completely drain the cooling system a Disconnect the negative battery terminals b Remove the radiator petcock drain valve c Remove the two 2 8mm Allen plugs Fa
6. nders using fresh sealant for each cylinder Leave injector bores open and allow it to cure for 24 hours DO NOT attempt to start or turn the key to the on position in your vehicle Ideal curing temperature is about 70 F Colder temperatures below freezing could require up to 72 hours to reach maximum strength s Repeat the test procedures on all repaired cylinder heads after the 24 hours have passed verifying the cracks are sealed Repeat the repair if necessary with a fresh pipette of sealant t Follow Ford factory procedure for injector reinstallation u Flush the cooling system completely following the Ford factory procedure Be sure to replace change any necessary O rings and hoses Stage 4 Other Considerations K 7 ss 4 VA wae e 4 Wt mr MING Hee yn A PPT NOTE The large O ring between the intake manifold and the front engine cover is highly prone to failure from fuel contamination We highly recommend you replace it at this time NOTE We recommend you replace any coolant system hoses that may be contaminated or compromised PEs Cylinder Head Test and Repair Kit BulletProofDiesel com Recommended O ring hose and hardware replacements P N Fuel injector O rings 6000042 Stand pipes 2003 early 2004 oun Stand pipes amp dummy plugs set 2005 2007 F series eo 2005 2010 E series HPOP connector fitting upgrade kit 2004 5 2007 F series 6000034 2005 2010 E series Degas bottle cap 1
7. ose Install the 1 8 pipe thread end of the pressure manifold and hydraulic hose to the repair tool Connect a grease gun to the zerk fitting on the pressure manifold Pump the grease gun until the pressure reaches 500psi This will inject the sealer into the identified crack m Remove the grease gun from the pressure manifold and observe the pressure gauge for 10 15 minutes the pressure should drop as fluid enters the crack Th oda a S AU 16 Cylinder Head Test and Repair Kit BulletProofDiesel com n Once the pressure has dropped to near zero or after 15 minutes remove and clean the repair tool using a solvent o Leave the pressure manifold and hydraulic hose charged with the grease gun for the next repair p After removing the tool clean and dry the injector bore NOTE DO NOT use impact or air tools of any kind When removing the tool carefully loosen the injector hold down bolt The bolt will break loose initially then feel tight again Once the bolt feels tight again slowly loosen the bolt by hand with consistent and even pressure applied This consistent pressure will ensure the injector hold down does not become damaged upon removal If the tool does not come out by hand stop and call us NOTE DO NOT use fluids or solvents to clean the injector bore We recommend using a dry shop towel me Cylinder Head Test and Repair Kit BulletProofDiesel com q Repeat as necessary on all cracked cyli
8. r towel tear off enough to form a gumball sized plug and place it into the injector bore This is to prevent the sealant from entering the cylinder Failure to do so may cause engine damage ee Cylinder Head Test and Repair Kit BulletProofDiesel com g Push the paper towel plug to the bottom of the injector bore Make sure the paper plug is fully seated in the stainless steel injector cup Be sure to clean the injector hold down bolt hole Re h Install the repair tool into the injector bore and torque to 24 foot pounds NOTE DO NOT use impact or air tools of any kind when installing the injector bore tool While installing the tool into the cylinder head slowly tighten the injector hold down bolt while holding the tool as close as possible to center This will help to ensure the tool goes into the injector bore straight and does not bind during installation i Cylinder Head Test and Repair Kit BulletProofDiesel com i Verify the clamp and repair tool are fully seated we e j Cut the tip off the pipette containing the cylinder head sealant and fill the sealant passage in the center of the tool One 1 pipette of sealant will repair one 1 crack 15 Cylinder Head Test and Repair Kit BulletProofDiesel com k Prime the pressure manifold with grease using a grease gun until grease comes out of the end of the hydraulic hose This removes the air from the inside of the pressure manifold and hydraulic h
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