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Cylinder Sleeve Trimming

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Fig 1: Cylinder Liner Trimming Tools View (1 Of 2)
GM1253966Courtesy of GENERAL MOTORS CORP.

The EN-45680-861:  trim tool assembly (2) contains or requires the following components to complete 2.4L, 88 mm cylinder sleeve trimming:

Fig 2: Cylinder Liner Trimming Tools View (2 Of 2)
GM1253969Courtesy of GENERAL MOTORS CORP.
    Fig 3: View of New Cylinder Bore Sleeve
    GM2146325Courtesy 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.
  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-45680-884:  metal shaving catch plug (1) 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 additional EN-45680-884:  metal shaving catch plugs into all remaining cylinder bore sleeves.
    4. Fig 4: View of Metal Shaving Catch Plug
    GM2146326Courtesy 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 EN-45680-884:  metal shaving catch plug (1) 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 chamfer bit are installed on EN-45680-861:  trimmer base assembly :
    • EN-45680-881:  chamfer bit, 88 mm sleeve
    • EN-45680-885:  trimmer pilot, 88 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 EN-45680-886:  gage ring assembly should be positioned upward on a flat surface.
    7. Fig 6: View Of Trim Tool Assembly Components And Positioning
    GM1253983Courtesy of GENERAL MOTORS CORP.
    NOTE: Ensure that the set gage ring on the gage ring assembly surfaces are clean.
  7. Carefully position 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) 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 EN-45680-861 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 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 four EN-45680-864:  bolts (2) 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 EN-45680-866:  drive adapter (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 (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 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, gradually apply downward force until the cutting action is complete in approximately 5 seconds.
  16. Remove EN-45680-866:  drive adapter (1) and drill assembly from EN-45680-861:  trim tool assembly.
  17. Turn off the compressed air valve (2).
  18. Remove EN-45680-861:  trim tool assembly from the engine block.
  19. Remove any material shavings that may be found on the metal shaving catch plug.
  20. Wipe the cylinder bore sleeve and surrounding areas free of any powder residue and then remove EN-45680-884:  metal shaving catch plug.
    21. Fig 9: Identifying Light & Straight Edge
    GM2146327Courtesy of GENERAL MOTORS CORP.
  21. Install a straight edge (2) on the cylinder block perpendicular to the crankshaft center line.
  22. Using a light (1), illuminate the backside of the straight edge.
    23. Fig 10: Checking For Proper Cut Measurement Of Cylinder Bore Sleeve
    GM2146328Courtesy of GENERAL MOTORS CORP.
  23. Looking at the front of the straight edge (1), 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 (2), the cylinder bore sleeve is cut incorrectly and a new cylinder bore sleeve needs to be installed.
    24. Fig 11: Identifying Correct Cylinder Bore Sleeve Cut
    GM2146329Courtesy of GENERAL MOTORS CORP.
  24. Looking at the front of the straight edge (1), 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 (2) is cut correctly.
  25. Proceed to the next bore sleeve to be trimmed repeating steps 10-23 if necessary.
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