SMU -New Cylinder Bore Piston Sleeve Replacement Procedure

This bulletin is being revised to update model years, bulletin content, add parts information and the tool part number in the Warranty information and the Cylinder Sleeve Trimming/Trim Tool Cutter information. Please discard Corporate Bulletin Number 04-06-01-022A (Section 06 -- Engine/Propulsion System).

A new procedure has been developed to replace the cylinder bore sleeves in the 2.8L, 3.5L and 4.2L engines. This procedure has been added to the Service Manual in the Engine Mechanical sub-section. This procedure may be used when the engine is in or out of the vehicle.

Notice: 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.

Notice: Do not damage the crankshaft connecting rod journals or reluctor ring or engine damage will occur.

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.
2. Install the cylinder bore sleeve puller EN 45680-402 (1), which is part of EN 45680-400, through the cylinder bore.

Notice: Ensure that the shoe is flat against the bottom of the cylinder bore sleeve or damage to the cylinder bore sleeve puller EN 45680-402 will occur.

3. Align the shoe (1) of the cylinder bore sleeve puller EN 45680-402 to the bottom of the cylinder bore sleeve (117).



4. Hold the threaded shaft of the cylinder bore sleeve puller EN 45680-402 upward in order to retain the shoe alignment to the bottom of the cylinder bore sleeve.
5. Install the fixture EN 456850-401 (4) onto the threaded shaft of the cylinder bore sleeve puller EN 456850-402 and the engine block.
6. Install the bearing (3) and the nut (1).
7. Tighten the nut (1) to the bearing (3).

Important: Use four old cylinder head bolts for the attaching bolts.

8. Install and tighten the 4 attaching bolts (2) into the cylinder head bolt holes of the block.

Tighten
Tighten the bolts to 15 N·m (11 lb ft).




9. Rotate the nut clockwise in order to remove the cylinder bore sleeve.



10. Remove fixture EN 45680-401, cylinder bore sleeve puller EN 45680-402, and the cylinder bore sleeve (117) from the engine block.
11. Loosen the nut (1) in order to remove the cylinder bore sleeve (117).
12. Inspect the cylinder bore in the cylinder block for cracks or damage. If cracked or damaged, replace the cylinder block.
13. Inspect the piston, piston rings, and connecting rod for damage. Refer to Piston, Connecting Rod, and Bearings Cleaning and Inspection.

Notice: 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.

Notice: 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.




1. Place the NEW cylinder bore sleeve (117), P/N 88984239, onto the cylinder block.
2. Install fixture EN 45680-401/cylinder bore sleeve installer EN 45680-403 assembly (1), which is part of EN 45680-400, 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 fixture EN 45680-401 (1).

Notice: Refer to Fastener Notice in Cautions and Notices.

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 N·m (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 cylinder bore sleeve installer EN 45680-403 into the groove of fixture EN 45680-401 (1).




Notice: Do not use any air powered or electric tools to rotate the threaded shaft of the fixture EN 45680-401/cylinder bore sleeve installer EN 45680-403 assembly or damage to the cylinder bore sleeve will occur.

8. Using a ratchet, rotate the threaded shaft of fixture EN 45680-401/cylinder bore sleeve installer EN 45680-403 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 inch (1.6 mm) of the cylinder bore sleeve above the surface of the cylinder block.



10. Using a torque wrench, torque the threaded shaft of the fixture EN 45680-401/cylinder bore sleeve installer EN 45680-403 assembly to 102 N·m (75 lb ft) in order 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. Remove the fixture EN 45680-401/cylinder bore sleeve installer EN 45680-403 assembly (1) from the cylinder block (100).

Trim Tool Cutter

Notice: Please ensure that the cylinder bore sleeve trim tool has been updated with the new trimmer pilot. The old trimmer pilot, black in color for identification, may cause damage to the tool or to the sleeve.

An updated trimmer pilot (EN-45680-499) was sent in November, 2004 to affected Chevrolet and GMC dealers. The new pilot is white in color, and should be installed on EN-45680-411 Trim Tool Assembly. Buick and HUMMER dealers were sent EN-45680-400 Cylinder Liner Replacer kit with the correct pilot already installed. Inspect EN-45680-411 to ensure the correct white pilot is installed.

The trim tool cutter with the new trimmer pilot can be viewed from the bottom of the tool. Refer to the illustration above.

1. After installing the NEW cylinder bore sleeve(s) into the engine block, trim the excess material from the cylinder bore sleeve flange.
2. Place metal shaving catch plug EN 45680-413 into the cylinder bore sleeve to be trimmed. Position the top of the EN 45680-413 approximately 3.0 mm (0.12 in) below the top surface of the cylinder bore sleeve.
3. Place additional metal shaving catch plugs EN 45680-413 into all remaining cylinder bore sleeves.



4. Ensure that the metal shaving catch plug EN 45680-413 is 3.0 mm (0.12 in) below the top surface of the cylinder bore sleeve.




Important: Before using trim tool assembly EN 45680-411, 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 set gage ring EN 45680-412 (1) should be positioned upward on a flat surface.




Important: Ensure that the set gage ring EN 45680-412 surfaces are clean.

6. Carefully position trim tool assembly EN 45680-411 onto the set gage ring EN 45680-412.
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).

Important: Once this procedure is done, it is not necessary to reset the trim tool assembly EN 45680-411 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.

Tighten
Tighten the shaft collar screw to 19 N·m (14 lb ft).




10. Place trim tool assembly EN 45680-411 onto the cylinder to be trimmed with the directional arrow (1) pointing in line with the crankshaft centerline and the front of the block.
11. Install the 4 bolts EN 45680-414 (2) into the cylinder head bolt holes in the block.

Tighten
Tighten the bolts to 20 N·m (15 lb ft).




12. Fasten drive adapter EN 45680-866 (1) into the drill chuck.
13. Connect a compressed air supply 517-862 kPa (75-125 psi) to the male quick connect (3) located on trim tool assembly EN 45680-411. Turn the compressed air valve (2) to the open position. This starts the venturi vacuum system that will catch the metal shavings.
14. Place drive adapter EN 45680-866 and drill assembly (1) vertically onto the drive adapter end of trim tool assembly EN 45680-411. 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 drive adapter EN 45680-866 (1) and drill assembly from the trim tool assembly EN 45680-411.
16. Turn off the compressed air valve (2).
17. Remove trim tool assembly EN 45680-411 from the engine block.
18. Remove any material shavings that may be found on the metal shaving catch plug EN 45680-413.
19. Wipe the cylinder bore sleeve and surrounding areas free of any powder residue and then remove the metal shaving catch plug EN 45680-413.



20. Install a straight edge on the cylinder block perpendicular to the crankshaft center line.
21. Using a light, illuminate the backside of the straight edge.



22. 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 of 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.



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 block deck surface. If light is present on both sides of the cylinder block, the cylinder bore sleeve is cut correctly.
24. Proceed to the next cylinder bore sleeve to be trimmed repeating steps 10-23 if necessary.

For vehicles repaired under warranty, use:

S/T Utility

S/T Pickup

*A one time tool allowance for the cost of the tool EN 45680-400 may be claimed. This is in lieu of packaging this as an essential tool since all dealers may not require this process. This tool will be shipped to Tier 1 and Tier 2 dealers in the USA and high volume dealers in Canada. Other dealers may order the tool from Kent Moore. This tool allowance should be filed under Z2076 for the cost of the tool, minus shipping and taxes and should be entered in the net amount category. This claim should be filed with the first use of the tool and "H" routed to the Area Service Manager (DSM in Canada) for approval. As with any net amount claim, supporting documentation must be attached to the repair order. This allowance may only be claimed one time per BAC/dealer code. Any dealer that has received this tool and not used it after a period of five years may return the entire tool to Kent Moore for a refund of the original purchase price not including shipping or taxes. Contact Kent Moore at 1-800-GMTOOLS (1800-468-6657) or fax 1-800-578-7375 to obtain a return authorization and shipping instructions.

If you have already performed the repair, but did not submit for credit for the tool, please submit now.