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Home >> GMC Truck >> 2005 >> Canyon 2WD L4-2.8L VIN 8 >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Service and Repair >> Overhaul >> Repair Instructions >> 49. Cylinder Liner Installation >> Cylinder Liner Trimming

Cylinder Liner Trimming

NOTE: The content of this article/image reflects the changes called out by TSB: 04-06-01-022B.

Cylinder Liner Trimming





^ EN 45680-865 Debris Collector (3)
^ EN 45680-411 Trim Tool Assembly (2)
^ Air Control Valve (1 - Part of EN 45680-411
^ Drill Motor with 1/2 inch chuck, 1 1/8 hp. 7 amps, triple gear reduction, and a 450-600 RPM rotational speed in a clockwise direction


Trim Tool Cutter



NOTE: 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.







^ Trim Tool Preloader (1)
^ EN 45680-412 Set Gage Ring (2)
^ EN 45680-413 Metal Shavings Catch Plug (3)
^ EN 45680-866 Drive Adapter (4)
^ EN 45680-414 Bolts (5)






Notice: Do not bore or hone the cylinder bore liner. The cylinder bore liner 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 liner(s) into the engine block, trim the excess material from the cylinder bore liner flange.

Notice: Ensure that all the metal particles are collected in order to prevent internal damage to the transaxle or bearings.

2. Place metal shaving catch plug EN 45680-413 into the cylinder bore liner to be trimmed. Position the top of the EN 45680-413 approximately 3.0 mm (0.12 inch) below the top surface of the cylinder bore liner.
3. Place additional metal shaving catch plugs EN 45680-413 into all remaining cylinder bore liners.






Notice: Installing the metal shaving catch plug EN 45680-413 deeper than the recommended depth will create a decrease in vacuum system performance. A decrease in vacuum system performance will cause mental shavings to enter the engine and cause engine failure.

Notice: Installing the metal shaving catch plug EN 45680-413 above the recommended depth will cause damage to the metal shaving catch plug EN 45680-413.

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






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 liner flange must be flush to +0.02 mm (0.0008 inch) above the block deck surface.

5. The groove side of the set gage ring EN 41680-412 (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 4'i680-411 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 the shaft collar screw to 19 Nm (14 ft. lbs.).





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 the bolts to 20 Nm (15 ft. lbs.).






Notice: 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 liner will occur.

12. Fasten drive adapter EN 45680-866 (1) into the drill chuck.

Notice: 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 (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 45680-411Do 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 liner 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 liner flange. If light is present of either side or both sides of the cylinder bore liner, the cylinder bore [liner is cut incorrectly and a new cylinder bore [liner 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 liner is cut correctly.
24. Proceed to the next bore liner to be trimmed repeating steps 10-23 if necessary.
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