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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1923 (Engine Mechanical - 2.4L) >> Repair Instructions - On Vehicle >> Cylinder Sleeve Replacement >> Cylinder Liner Trimming

Cylinder Liner Trimming

WARNING: This page is about a different car, the 2009 Saturn Vue. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Cylinder Liner Trimming Tools View (1 Of 2)
GM1253966Courtesy of GENERAL MOTORS CORP.
Fig 2: Cylinder Liner Trimming Tools View (2 Of 2)
GM1253969Courtesy of GENERAL MOTORS CORP.
    CAUTION: Do not bore or hone the cylinder bore sleeve. The cylinder bore sleeve inside diameter (I.D) is fully machined and honed to size and is optimally finished as shipped. Any attempt to modify this factory-produced sizing and finish with additional boring and honing will lead to engine damage, excessive noise or abnormal oil consumption.
    Fig 3: View Of Metal Shaving Catch Plug
    GM1333483Courtesy of GENERAL MOTORS CORP.
  1. After installing the NEW cylinder bore sleeve(s) into the engine block, trim the excess material from the cylinder bore sleeve flange.
    2. CAUTION: Ensure that all the metal particles are collected in order to prevent internal damage to the engine or bearings.
  2. Place the EN 45680-883 metal shaving catch plug into the cylinder bore sleeve to be trimmed. Position the top of the EN 45680-883 approximately 3.0 mm (0.12 in) below the top surface of the cylinder bore sleeve.
  3. Place additional EN 45680-883 metal shaving catch plugs into all remaining cylinder bore sleeves.
    4. Fig 4: Identifying Catch Plug Positioning
    GM1253978Courtesy of GENERAL MOTORS CORP.
    CAUTION: Installing the metal shaving catch plug deeper than the recommended depth will create a decrease in vacuum system performance. A decrease in vacuum system performance will cause metal shavings to enter the engine and cause engine failure.
    CAUTION: Installing the metal shaving catch plug above the recommended depth will cause damage to the metal shaving catch plug.
  4. Ensure that the EN 45680-883 metal shaving catch plug is 3.0 mm (0.12 in) below the top surface of the cylinder bore sleeve.
    5. Fig 5: Identifying Set Gauge Ring Groove
    GM1253982Courtesy of GENERAL MOTORS CORP.
    NOTE: Before using EN 45680-881 trim tool assembly, the height of the cutting blades must be set to the proper specification. The proper specification is that the cylinder bore sleeve flange must be flush to +0.02 mm (0.0008 in) above the block deck surface.
  5. The groove side of the EN 45680-882 set gage ring (1) should be positioned upward on a flat surface.
    6. Fig 6: View Of Trim Tool Assembly Components And Positioning
    GM1253983Courtesy of GENERAL MOTORS CORP.
    NOTE: Ensure that the EN 45680-882 set gage ring surfaces are clean.
  6. Carefully position EN 45680-881 trim tool assembly onto the EN 45680-882 set gage ring.
  7. Loosen the shaft collar screw (2).
  8. Push the shaft collar (2) downward using the trim tool preloader (1) until the shaft collar is positioned against the top of the flange bearing (3).
    9. NOTE: Once this procedure is done, it is not necessary to reset the EN 45680-881 trim tool assembly height until the blades are worn or damaged.
  9. Apply downward pressure on the collar and inner drive shaft using the trim tool preloader (1), then tighten the shaft collar screw to 19 N.m (14 lb ft).
    10. Fig 7: Aligning Trim Tool Assembly
    GM1333473Courtesy of GENERAL MOTORS CORP.
  10. Place the EN 45680-881 trim tool assembly onto the cylinder to be trimmed with the directional arrow pointing in line with the crankshaft centerline and the front of the block.
  11. Install the EN 45680-884 4 bolts into the cylinder head bolt holes in the block and tighten to 20 N.m (15 lb ft).
    12. Fig 8: Identifying EN 45680-866
    GM1333459Courtesy of GENERAL MOTORS CORP.
    CAUTION: For proper tool operation, a drill motor with a 1/2 inch chuck, 1 1/8 hp, 7 amps, triple gear reduction, and a 450-600 RPM rotational speed in a clockwise direction must be used. If the proper drill motor is not used, damage to the cylinder bore sleeve will occur.
  12. Fasten the drive adapter EN 45680-886 into the drill chuck.
    13. CAUTION: Ensure that there are no crimps in the air feed hose or the vacuum hose. Crimps in the hose may cause metal shavings to exit the cutting tool in any direction, causing engine damage.
  13. Connect a compressed air supply (75-125 psi) to the male quick connect located on EN 45680-881 trim tool assembly. Turn the compressed air valve to the open position. This starts the venturi vacuum system that will catch the metal shavings.
  14. Place the EN 45680-886 drive adapter and the drill assembly vertically onto the EN 45680-881 drive adapter end of trim tool assembly. Do not apply downward force on the drill until full rotational speed has been reached. After reaching full rotational speed, gradually apply downward force until the cutting action is complete in approximately 5 seconds.
  15. Remove the EN 45680-886 drive adapter (1) and the drill assembly from the EN 45680-881 trim tool assembly.
  16. Turn OFF the compressed air valve.
  17. Remove the EN 45680-881 trim tool assembly from the engine block.
  18. Wipe the cylinder bore sleeve and the surrounding areas of any powder residue. Remove the EN 45680-883 metal shaving catch plug.
    19. Fig 9: Checking Cylinder Block Deck Surface With Straight Edge
    GM1415604Courtesy of GENERAL MOTORS CORP.
  19. Install a straight edge on the cylinder block perpendicular to the crankshaft centerline.
  20. Using a light, illuminate the backside of the straight edge.
    21. Fig 10: View Of Improperly Cut Cylinder Bore Sleeve
    GM1415606Courtesy of GENERAL MOTORS CORP.
  21. Looking at the front of the straight edge, inspect to see if light is protruding through the bottom of the straight edge and the top of the cylinder bore sleeve flange. If light is present on either side of both sides of the cylinder bore sleeve, the cylinder bore sleeve is cut incorrectly and a new cylinder bore sleeve needs to be installed.
    22. Fig 11: View Of For Properly Cut Cylinder Bore Sleeve
    GM1415607Courtesy of GENERAL MOTORS CORP.
  22. Looking at the front of the straight edge, inspect to see if light is protruding through the bottom of the straight edge and the top of the cylinder block deck surface. If light is present on both sides of the cylinder block, the cylinder bore sleeve is cut correctly.
  23. Proceed to the next bore sleeve to be trimmed, repeating steps 10-19 if necessary.
  24. Install the piston and the connecting rod. Refer to Piston, Connecting Rod, and Bearing Replacement .
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