Cylinder Liner: Service and Repair
The content of this article reflects the changes identified in TSB 03-06-01-018cBulletin No.: 03-06-01-018C
Date: October 24, 2005
SERVICE MANUAL UPDATE
Subject:
New Cylinder Bore Piston Sleeve Replacement Procedure
Models:
2002-2005 Chevrolet Cavalier
2004-2006 Chevrolet Classic, Malibu
2005-2006 Chevrolet Cobalt, Cobalt SS
2006 Chevrolet HHR
2002-2004 Oldsmobile Alero
2002-2005 Pontiac Sunfire
2002-2006 Pontiac Grand Am
2005-2006 Pontiac G6, Pursuit (Canada Only)
2006 Pontiac Soltice
with Ecotec 2.0L, 2.2L or 2.4L 4-Cylinder Engine (VINs P, F, B - RPOs LSJ, L61, LE5)
Cylinder Bore Sleeve Removal
Note: Be careful not to damage the crankshaft connecting rod journals or reluctor ring.
1. If the crankshaft is still installed, rotate the crankshaft so that the counterweight is to the right side and the connecting rod journal is to the left side and not in alignment with the cylinder bore.
Important: Use four old cylinder head bolts for the attaching bolts.
2. Install EN 45680-851(2) to the cylinder block while installing the EN 45680-852 (1) through the cylinder bore.
Note: Be sure the shoe is flat against the bottom of the cylinder bore sleeve or damage to the EN 45680-852 will occur.
3. Align the shoe (1) of EN 45680-852 to the bottom of the cylinder bore sleeve (117).
4. Hold the threaded shaft upward in order to retain the shoe alignment to the bottom of the cylinder bore sleeve. Tighten the nut (1) to the bearing (3).
5. Tighten the 4 attaching bolts (2) into the cylinder head bolt holes of the block.
Tighten
Tighten the bolts to 15 Nm (11 lb ft).
Note: Be careful not to damage the cylinder block surface. Damage to the cylinder block surface can cause engine failure.
6. Remove EN 45680-851, EN 45680-852, and the cylinder bore sleeve (117) from the engine block.
7. Loosen the nut (1) in order to remove the cylinder bore sleeve (117).
Cylinder Bore Sleeve Installation
1. Place the NEW cylinder bore sleeve (117), P/N 88984129, onto the cylinder block.
2. Install EN 45680-851/EN 45680-853 assembly (1) over the cylinder bore sleeve (117) and onto the cylinder block. Do not apply downward pressure to the cylinder bore sleeve (117).
Important: Use 4 old cylinder head bolts for the attaching bolts.
3. Insert the 4 attachment bolts into the legs of the EN 45680-851(1).
4. Tighten the 4 attachment bolts. Do not apply downward pressure to the cylinder bore sleeve (117).
Tighten
Tighten the 4 attachment bolts to 15 Nm (11 lb ft).
5. Align the bottom of the cylinder bore sleeve (117) with the cylinder bore of the block (100).
6. Align the installation arbor (1) onto the top of the cylinder bore sleeve (117).
7. Align the pusher block (2) of EN 45680-853 into the groove of EN 45680-851(1).
Note: Do not use any air or electric tools to rotate the threaded shaft of the EN 45680-851/EN 45680-853 assembly or damage to the cylinder bore liner will occur.
8. Using a ratchet, rotate the threaded shaft of EN 45680-851/EN 45680-853 assembly (1) 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 in (1.6 mm) of the cylinder bore sleeve assembly above the surface of the cylinder block.
10. Using a torque wrench, the cylinder bore liner can be completely seated in place when the threaded shaft is torqued to 102 N.m (75 lb-ft). With the liner properly installed, a minimal portion of the sleeve flange will protrude above the block deck surface.
11. Remove the EN 45680-851/EN 45680-853 assembly (1) from the cylinder block (100).
Cylinder Sleeve Trimming
Tools
Note:Please ensure that the cylinder bore sleeve trim tool has been updated with the new trimmer pilot (1). The old trimmer pilot, black in color for identification, may cause damage to the tool or to the sleeve. An updated trimmer pilot (EN 45680-899) was sent in November, 2004 to affected Chevrolet and Pontiac dealers. The new pilot is white in color and should be installed on EN 45680-861 Trim Tool Assembly. Inspect EN 45680-861 to ensure the correct white pilot is installed.
Tools
The trim tool cutter with the new trimmer pilot can be viewed from the bottom of the tool. Refer to the illustration above.
Note: After installing the new cylinder bore sleeves into the engine block, trim the excess material from the top area of the cylinder bore liners. It is important that all the material shavings are collected so they do not cause engine damage.
1. Place EN 45680-863 into the cylinder to be trimmed. Position the top of the EN 45680-863 approximately 4.7 mm (3/16 in) below the top surface of the liner.
2. Place additional EN 45680-863s into adjacent cylinders.
Note:Installing the EN-45680-863 deeper than the recommended depth will create a decrease in vacuum system performance. Decrease in vacuum system pressure will cause metal shavings to enter the engine and cause engine failure.
Note:Installing the catch plug above the recommended depth will cause damage to the plug.
3. Ensure that the EN 45680-863 is 4.7 mm (3/16 in) below the top surface of the sleeve.
Important: Before using EN 45680-861 the height of the cutting blades must be set to the manufacturers specifications. The manufacturers specifications indicate that the cylinder bore sleeve top face must be flush to +0.02 mm (0.0008 in) above the deck surface. The recessed area (1) of the set gage ring should be positioned upward and facing the cutting tool.
4. Position EN 45680-862 assembly onto a flat surface.
Important: Ensure that the surfaces are clean.
5. Carefully position EN 45680-861 onto the set gage ring.
6. Loosen the shaft collar (2).
7. 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).
Important: Once this procedure is done, it is not necessary to reset the height for the remaining cylinders until the blades are worn to the point of non-compliance or blade replacement has been performed.
8. Holding downward pressure on the collar and inner drive shaft using the trim tool preloader (1), securely tighten the shaft collar screw.
Tighten
Tighten the shaft collar screw to 19 Nm (14 lb ft).
9. Place EN 45680-861 onto the cylinder to be trimmed with the directional arrow (1) pointing in line with the crankshaft centerline and the front of the block.
10. Install the 4 EN 45680-864 (2) into the cylinder head bolt holes in the block.
Tighten
Tighten the bolts progressively to 20 Nm (15 lb ft).
11. Fasten EN 45680-866 (1) into the drill chuck.
Note: Ensure there are no kinks in the air feed hose or the vacuum hose. Kinks in the hose may cause metal shavings to exit the cutting tool in any direction, which can cause possible engine damage.
12. Connect a compressed air supply (75-125 psi) (517-862 kpa) to the male quick connect (3) located on EN 45680-861. Turn the compressed air valve (2) to the open position. This starts the venturi vacuum system that will catch the metal shavings.
13. Place EN 45680-866/drill (1) vertically onto the ball end of EN 45680-861. Do not apply downward force on the drill until the full rotational speed has been reached. After reaching full rotational speed, gradually apply downward force until the cutting action is complete - approximately 10 seconds.
14. Remove EN 45680-866 (1) from the EN 45680-861.
15. Turn off the compressed air valve (2).
16. Remove EN 45680-861 from the engine block.
17. Remove any material shavings that may be found resting on the EN 45680-863.
18. Remove EN 45680-863 and wipe the cylinder bore and surrounding areas free from any powder residue.
19. Proceed to the next cylinder bore sleeve to be trimmed repeating steps 6-14.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
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