Cylinder Liner Trimming
Tools
1. EN-45680-865 Debris Collector
2. EN-45680-861 Trim Tool Assembly
3. Air Control Valve
4. 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 rotation
Tools
1. Trim Tool Preloader
2. EN-45680-862 Set Gage Ring
3. EN-45680-863 Metal Shavings Catch Plug
4. EN-45680-866 Drive Adapter
5. EN-45680-864 Bolts
Notice:
After installing the new cylinder bore liners 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.
Notice:
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.
Notice:
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 liner.
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 bore liner 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 N.m (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 N.m (15 lb ft).
11. Fasten EN 45680-866 (1) into the drill chuck.
Notice:
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) 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 cuffing 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 bore liner to be trimmed repeating steps 6-14.