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Home >> Chevrolet >> 2009 >> HHR SS, Standard >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 3 (Engine Mechanical - 2.2L Or 2.4L) >> Repair Instructions - Off Vehicle >> Cylinder Sleeve Installation (2.2L) >> Cylinder Sleeve Trimming

Cylinder Sleeve Trimming

WARNING: This page is about a different variant/trim than selected.
Fig 1: Identifying Cylinder Liner Trimming Tool Components (1 Of 2)
GM1253966Courtesy of GENERAL MOTORS CORP.

The EN 45680-861:  trim tool assembly (2) contains or requires the following components to complete 2.2L, 86 mm cylinder sleeve trimming:

Fig 2: Identifying Cylinder Liner Trimming Tool Components (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: Placing Metal Shaving Catch Plug Into Cylinder Bore Sleeve
    GM1253974Courtesy 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 EN 45680-863:  metal shaving catch plug into the cylinder bore sleeve to be trimmed. Position the top approximately 3.0 mm (0.12 in) below the top surface of the cylinder bore sleeve.
  3. Place an additional EN 45680-863:  metal shaving catch plug 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 45680-863:  metal shaving catch plug is 3.0 mm (0.12 in) below the top surface of the cylinder bore sleeve.
  5. Ensure that the correct bore trimmer pilot and cutter bit are installed on the EN 45680-861:  trimmer base assembly :
    • EN 45680-869:  cutter bit and screw
    • EN 45680-899:  trimmer pilot, 86 mm sleeve
    6. Fig 5: Identifying Set Gauge Ring Groove
    GM1253982Courtesy of GENERAL MOTORS CORP.
    NOTE: Before using the 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.
  6. The groove side of the set gage ring (1) on the EN 45680-862:  gage ring assembly should be positioned upward on a flat surface.
    7. Fig 6: View Of Trim Tool Assembly Components & Positioning
    GM1253983Courtesy of GENERAL MOTORS CORP.
    NOTE: Ensure that the set gage ring surfaces are clean.
  7. Carefully position the EN 45680-861:  trim tool assembly onto the set gage ring.
  8. Loosen the shaft collar screw (2).
  9. Push the shaft collar (2) downward using the trim tool preloader (1) on the EN 45680-862:  gage ring assembly until the shaft collar is positioned against the top of the flange bearing (3).
    10. NOTE: Once this procedure is done, it is not necessary to reset the trim tool assembly height until the blades are worn, damaged, or replaced.
  10. 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).
    11. Fig 7: Aligning Trim Tool Assembly
    GM1253992Courtesy of GENERAL MOTORS CORP.
  11. Place the EN 45680-861:  trim tool assembly onto the cylinder to be trimmed with the directional arrow (1) pointing in line with the crankshaft centerline and the front of the block.
  12. Install the EN 45680-864 (2):  4 bolts into the cylinder head bolt holes in the block and tighten to 20 N.m (15 lb ft).
    13. Fig 8: View Of Drive Adapter
    GM1253994Courtesy 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.
  13. Fasten the drive adapter EN 45680-866 (1) into the drill chuck.
    14. 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.
  14. Connect a compressed air supply 517.10-861.84 kPa (75-125 psi) to the male quick connect (3) located on EN 45680-861:  trim tool assembly. Turn the compressed air valve (2) to the open position. This starts the venturi vacuum system that will catch the metal shavings.
    15. NOTE: It should not take longer than 15 seconds to complete the trimming procedure. If it does, the trimming bits must be repositioned to a new cutting surface.
  15. Place the EN 45680-866:  drive adapter and drill assembly (1) vertically onto the drive adapter end of EN 45680-861:  trim tool assembly. Do not apply downward force on the drill until full rotational speed has been reached. After reaching full rotational speed, apply firm downward force until the cutting action is complete.
  16. Remove the EN 45680-866 (1):  drive adapter and drill assembly from the EN 45680-861:  trim tool assembly.
  17. Turn off the compressed air valve (2).
  18. Remove the EN 45680-861:  trim tool assembly from the engine block.
  19. Remove any material shavings that may be found on the EN 45680-863:  metal shaving catch plug.
  20. Wipe the cylinder bore sleeve and surrounding areas free of any powder residue and then remove the EN 45680-863:  metal shaving catch plug.
    21. Fig 9: Checking Cylinder Block Deck Surface With Straight Edge
    GM1415604Courtesy of GENERAL MOTORS CORP.
  21. Install a straight edge on the cylinder block perpendicular to the crankshaft center line.
  22. Using a light, illuminate the backside of the straight edge.
    23. Fig 10: View Of Improperly Cut Cylinder Bore Sleeve
    GM1415606Courtesy of GENERAL MOTORS CORP.
  23. Looking at the front of the straight edge, check 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 or both sides of the cylinder bore sleeve, the cylinder bore sleeve is cut incorrectly and a new cylinder bore sleeve needs to be installed.
    24. Fig 11: View Of Properly Cut Cylinder Bore Sleeve
    GM1415607Courtesy of GENERAL MOTORS CORP.
  24. Looking at the front of the straight edge, check 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.
  25. Proceed to the next bore sleeve to be trimmed repeating steps 10-23 if necessary.
    CAUTION: Do not use assembly aids or lubricants on the cylinder bore sleeve or the cylinder bore block when installing a new cylinder bore sleeve, or engine damage will occur. These items will not aid in the installation of the new cylinder bore sleeve.
    CAUTION: Do not chill or heat the cylinder bore sleeve or the cylinder block when removing or installing a new cylinder bore sleeve. Chilling or heating the cylinder bore sleeve or the cylinder block will cause engine damage and will not aid the removal or installation of the new cylinder bore sleeve.
    Fig 12: View Of Cylinder Bore Sleeve Fixture
    GM1253945Courtesy of GENERAL MOTORS CORP.
  1. Place the NEW cylinder bore sleeve (117) onto the cylinder block.
  2. Install the fixture EN-45680-851:  fixture and the EN-45680-853:  cylinder bore sleeve installer (1) over the cylinder bore sleeve (117) and onto the cylinder block. Do not apply downward pressure to the cylinder bore sleeve (117).
    3. Fig 13: View Of Cylinder Bore Sleeve Puller & Attachment Bolts
    GM1253946Courtesy of GENERAL MOTORS CORP.
    NOTE: Use 4 old cylinder head bolts for the attaching bolts.
  3. Insert the 4 attachment bolts into the legs of the fixture EN-45680-851 (1).
    4. CAUTION: Refer to Fastener Caution .
    NOTE: Do not apply downward pressure to the cylinder bore sleeve (117).
  4. Tighten the 4 attachment bolts to 15 N.m (11 lb ft).
    5. Fig 14: View Of Proper Liner Alignment
    GM1253949Courtesy of GENERAL MOTORS CORP.
  5. Align the bottom of the cylinder bore sleeve (117) with the cylinder bore of the block (100).
    6. Fig 15: View Of Installation Arbor
    GM1253954Courtesy of GENERAL MOTORS CORP.
  6. Align the installation arbor (1) of the EN-45680-853:  cylinder bore sleeve installer onto the top of the cylinder bore sleeve (117).
    7. Fig 16: View Of Pusher Block
    GM1253956Courtesy of GENERAL MOTORS CORP.
  7. Align the pusher block (2) of the EN 45680-851:  cylinder bore sleeve installer into the groove of fixture (1).
    8. Fig 17: View Of Cylinder Bore Sleeve, Engine & Installation Using Tool
    GM1253957Courtesy of GENERAL MOTORS CORP.
    CAUTION: Do not use any air powered or electric tools to rotate the threaded shaft of the cylinder bore sleeve installer in the fixture assembly or damage to the cylinder bore sleeve will occur.
  8. Using a ratchet, rotate the threaded shaft of the EN 45680-853 (1):  cylinder bore sleeve installer in order to install the cylinder bore sleeve (117) into the engine block (100).
  9. Do not completely seat the cylinder bore sleeve in the block. Leave approximately 1/16 inch of the cylinder bore sleeve above the surface of the cylinder block.
    10. Fig 18: Illustrating Cylinder Bore Sleeve Seating
    GM1253960Courtesy of GENERAL MOTORS CORP.
  10. Using a torque wrench, torque the threaded shaft to 102 N.m (75 lb ft) to completely seat the cylinder bore sleeve in the cylinder block. With the cylinder bore sleeve properly installed, a minimal portion of the cylinder bore sleeve flange will protrude above the block deck surface.
    11. Fig 19: View Of Service Tool Assembly
    GM1253963Courtesy of GENERAL MOTORS CORP.
  11. Remove the EN 45680-851:  fixture assembly with the EN 45680-853 (1):  cylinder bore sleeve installer from the cylinder block (100).
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