#03-06-01-018D: SMU - New Cylinder Bore Piston
Contents
1. SESS Re SASS Se SSS Sse S NE ES AS ARS TEE AAAS CAN SUN EIE ARS ERE SANE SAA NUS ANS Stanek aS SASS SASS S SOS _ _ i S ES SASS Raa m SENS SSS SS SSS Saas SSS SS SESE Ss SSS SSS ANSA SS SS SENS SENSUM SSNS SAS SSS SERS SSS SENSN SSR ES SS SS RSS ARS 5 SESS SSS y SN NNUS RN SSS SESS SSS Sas SS SS US SENS _ S SSS RN SN SERS SESS SSS SS SS _ IS SS _ SEER RSS SEAS Se Se SSS SESS x SARS SSS SESS SSS S SS S SS SESS SERM SERS SS SSS Se SENSES S SS _ SAS SESS SE SSS SSS SSSR Sas SSS SS NN SENS SSN WS SSS SESS SN AS DES SSS SESS SSeS ESSEN SSSR SERS AS SS NM SN SES Sass SSS SS SS Sra SARS SEN SENSN um SNR SRM SNR SERS Sas SSS _ SW into installer e Ins sleev bore linde a 45 EN of E re k 2 1 fixtu bloc 85 the Align OVE O 6 gro the KI Dy K SS ded threa 853 the 80 te 56 rota EN 4 Is to ller ic too insta In or Mis ill o 0 85 1 cyiinder bo iii 85 bor not ea ice fix E Noti f the mag ft o r da sha bly o m asse EN and ixture the 85 fix insta 80 to 456 der EN in or the ft of bly eave of ded he block surface he zeve installer T the t e block eve a tate sleev ine sle eve t ro ore eng bore sle chet rb he inder ore lisi piss ares 7 680 s2. RRO _ St SESS _ S SS _ S _ _ SNS SS SESS SS TuS RN R SSSR SSS M NSW as SS NS NY SN REN SN AE RM ENS Sas RRS NS SR SS y Ri CIENT SUE ESSE AS SS SS SS kta SRS See ES S VASA SWR SSS SSS S SORS SN S S _ _ S S S S S SS SS E DASS NS SAN XS NS ROS SS SENS SS SS SES SSS SS YS aS 2 _ S _ S S _ S i o US RN CRS ES 851 m 80 2N 456 10 the mbly cyli f ft of asse in the lon O d sha taller iub par ade INS slee ima ce n the s Vii s surfa ighte r cylin talle lock h tig linde the INS eb ue 15680 853 pan sve properly i rq V e 9 U ture in or linde nge fix ft cy fla Ib ft the ner 75 With bo bloc linde y the c i HE 10 Remove the EN 45680 851 fixture and EN 45680 853 cylinder bore sleeve installer assembly 1 from the cylinder block 2 Cylinder Liner Trimming d EN 45680 865 Debris Collector 3 EN 45680 861 Trim Tool Assembly 2 Air Control Valve 1 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 le Trim Tool Preloader 1 EN 45680 862 Set Gage Ring 2 EN 45680 863 Metal Shavings Catch Plug 3 EN 45680 866 Drive Adapter 4 EN 45680 864 Bolts 5 Notice Do not bore or hone the cylinder bore sleeve The cylinder
3. 03 06 01 018D SMU New Cylinder Bore Piston Sleeve Replacement Procedure Apr 5 2006 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 VI Ns P B RPOs LS L61 LE5 This bulletin ts being revised to provide updated cylinder sleeve replacement procedures Please discard Corporate Bulletin Number 03 06 01 018C Section 06 Engine This bulletin is being issued to update cylinder sleeve replacement in the Engine Mechanical sub section of the Service Manual Please replace the current information in the Service Manual with the following information The following information has been updated within SI If you are using a paper version of this Service Manual please make a reference to this bulletin on the affected page The new procedure for the 2 0L 2 2L and 2 4L four cylinder engines has been developed to replace the cylinder bore sleeve when the engine 1 in or out of the vehicle Tools Required EN45680 850 Cylinder Sleeve Removal and Installation Kit Removal Procedure Notice Do not chill or heat the cylinder bore sleeve or the cylinder block when removing or installing a new cylinder b
4. the correct location Replacement fasteners must be the correct part number for that application Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure Do not use paints lubricants or corrosion inhibitors on fasteners or fastener joint surfaces unless specified These coatings affect fastener torque and joint clamping force and may damage the fastener Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems Important Use 4 old cylinder head bolts for the attaching bolts Insert the 4 attachment bolts into the legs of the EN 45680 851 fixture 1 Do not apply downward pressure to the cylinder bore sleeve 2 Tighten Tighten the 4 attachment bolts to 15 N m 11 Ib ft 4 Align the bottom of the cylinder bore sleeve 1 with the cylinder bore of the block 2 l sleev bore inder m the c of top onto the bor ion ar llatio insta ign the i Align 5 SRS _ ni NES SAR _ S SERS SS RS Ss E NS Si Patten SAS Ss ES NN IS SES RUN SESS S RENY SS z sed VENE SESS AY 5 SES XS mu SSS SN Sar SRS St SESS SS XN S SASS SSS nt SONS SONS 5 SSS SENS SASS SRM a ze pu SSS SA SSS SSE SESS AS SONS 5 SERS X SSS SS ARMS Sas SS V uS SSS AR
5. 0 861 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 The groove side of the EN 45680 862 set gage ring 1 should be positioned upward on a flat surface Important Ensure that the EN 45680 862 set gage ring surfaces are clean 6 Carefully position EN 45680 861 trim tool assembly onto the EN 45680 862 set gage ring 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 EN 45680 861trim tool assembly 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 Ib ft 000 9 MM NI 10 Place the EN 45680 861 trim tool assembly onto the cylinder to be trimmed with the directional arrow pointing in line with the crankshaft centerline and the front of the block 11 Install the EN 45680 864 4 bolts into the cylinder head bolt holes in the block Tighten Tighten the bolts to 20 N m 15 Ib ft 12 13 14 15 16 Remove the EN 45680 86
6. 1 trim tool assembly from the engine block 18 eee e 7A Qmm ZAR ES ov EV 20 ol SY OD HK Notice For proper tool operation a drill motor with 1 2 inch chuck 1 1 8 hp 7 amps triple gear reduction and 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 Fasten the drive adapter EN 45680 8660 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 Connect a compressed air supply 75 125 psi to the male quick connect located on EN 45680 861 trim tool assembly Turn the compressed air valve to the open position This starts the venturi vacuum system that will catch the metal shavings Place the EN 45680 866 drive adapter and the drill assembly vertically onto the EN 45680 861 drive adapter end of 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 Remove the EN 45680 866 drive adapter 1 and the drill assembly from the EN 45680 861 trim tool assembly Turn OFF the compressed air valve Wipe the cylinder bore sl
7. 2 cylinder bore sleeve puller and the cylinder bore sleeve from the engine block 15 Inspect the cylinder bore in the cylinder block for cracks or damage If cracked or damaged replace the cylinder block Installation Procedure 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 DW Y 92 M X X y 2 aS oy TA ow A d Fi 6 2 N N f 2 L ATTI m m CEU A O mo 2 9 A lt 05 RS A LA Maks Can iain ZA MA QN O WW P nm o C ES q Y lt 1 Place the NEW cylinder bore sleeve onto the cylinder block 2 Install EN 45680 851 fixture and EN 45680 853 cylinder bore sleeve installer assembly over the cylinder bore sleeve and onto the cylinder block Do not apply downward pressure to the cylinder bore sleeve Fastener Notice Use the correct fastener in
8. bore sleeve inside diameter 1 0 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 Notice Ensure that all the metal particles are collected in order to prevent internal damage to the transaxle or bearings 2 Place the EN 45680 863 metal shaving catch plug into the cylinder bore sleeve to be trimmed Position the top of the EN 45680 863 approximately 3 0 mm 0 12 in below the top surface of the cylinder bore sleeve 3 Place additional EN 45680 863 metal shaving catch plugs into all remaining cylinder bore sleeves SESS Notice Installing the metal shaving catch plug EN 45680 863 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 Notice Notice Installing the metal shaving catch plug EN 45680 863 above the recommended depth will cause damage to the metal shaving catch plug EN 45680 863 4 Ensure that the EN 45680 863 metal shaving catch plug is 3 0 mm 0 12 i below the top surface of the cylinder bore sleeve Important Before using EN 4568
9. eeve and the surrounding areas of any powder residue Remove the EN 45680 863 metal shaving catch plug 19 Install a straight edge on the cylinder block perpendicular to the crankshaft centerline 20 Using a light illuminate the backside of the straight edge je LA f 7 f f f f f f f f f BN NN NA Se Se SS S SS S ee 21 Looking at the front of the straight edge inspect 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 of both sides of the cylinder bore sleeve the cylinder bore sleeve is cut incorrectly and a new cylinder bore sleeve needs to be installed 225 23 24 25 26 S R N f f f f f f f f f f A f INS NSS a Se Se he he ee S SEN Looking at the front of the straight edge inspect 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 Proceed to the next bore sleeve to be trimmed repeating steps 10 19 if necessary Install the piston and the connecting rod Refer to Piston Connecting Rod and Bearing Installation Install the oil pan Refer to Oil Pan Replacement Install the cylinder head Refer to Cylinder Head Replacement
10. le sea of the 45 ia tely inch inde ple 6 in cylin t com 1 1 ot tely Don ima 8 FOX app k bloc inder cylin x vue SARS SSS SSS SERES E _ _ S S Se SS _ S SERS _ SN SSS 3 NN SS S _ S NS SES _ S SS S _ S SESS Sy SNAM SENA i Sy _ S ARN S SS AES SE L SSS SN SORS SRE lt SENS SSS SES SEN aud _ Se A SSS SERS M NNUS SSS Qu RRR SESS SESS SS SASS eRe SESS E SSS _ NN o S S ESS NS _ S Se E _ VY AS NEN _ UNS x ux n SN SEES SESS S SSS NS lt AES v S ER x S SY SS Soe SRS SESS SNS S v SSS Se S p S S S SESS S NC SSS _ SSS y SS _ SN RSS _ WES SENS S SES _ ES SO Eus _ SEE SAE XS i SMS SS SSS ES _ SSS x X RRS SSS SS SSS SSS lt S SSS lt RRRS lt SENS M GN RSEN S SSS SSS SONNEN VS SS SSN Ns SS SENSN _ SSS SAN SS SSNS SESS MS SRR SES RON SES SS NS _ SNR X EN SERIE SAS SS SONS SSS SSS Saas SESS S S RS SS XS SONS SN S URN S ERN SES SONS SASS SSS SS SS RS NESSUN SS RN SN SSS SERS SSS SSS XS SNR SESS SESS SESS SSSR a SERS SESS NEN RR SONS NM rM SERS SS SSS SS SONUS SESS p S S SS lt ERS S SSS SS SES SSS SSS i SAN SSS SSS SMS NES AA SS BRS SSS x SSS VS ESSEN SS SRM SSS Ss a ae SRS SENS SN EN SR _ S RUNS RN _ SSSNS _ SS
11. ore 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 Remove the cylinder head Refer to Cylinder Head Replacement Remove the oil pan Refer to Oil Pan Replacement Remove the piston and connecting rod Refer to Piston Connecting Rod and Bearing Removal Inspect the condition of the piston Refer to Piston Connecting Rod and Bearings Cleaning and Inspection 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 Install the EN 45680 852 cylinder bore sleeve puller 1 through the cylinder bore Notice Ensure that the shoe is flat against the bottom of the cylinder bore liner or damage to the cylinder bore liner puller EN45680 852 will occur Align the shoe 1 of the EN 45680 852 cylinder bore sleeve puller to the bottom of the cylinder bore sleeve 2 8 9 10 11 12 o Hold the threaded shaft of the EN 45680 852 cylinder bore sleeve puller upward in order to retain the shoe alignment to the bottom of the cylinder bore sleeve Install the EN 456850 851 fixture 4 onto the threaded shaft of the EN 456850 852 cylinder bore sleeve puller and the engine block Install
12. the bearing 3 and the nut 1 Tighten the nut 1 to the bearing 3 Fastener Notice Use the correct fastener in the correct location Replacement fasteners must be the correct part number for that application Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure Do not use paints lubricants or corrosion inhibitors on fasteners or fastener joint surfaces unless specified These coatings affect fastener torque and joint clamping force and may damage the fastener Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems I mportant Use 4 old cylinder head bolts for the attaching bolts 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 Ib ft ENIM pore m RR ON 13 Rotate the nut clockwise order to remove the cylinder bore liner qe PSM Oy a Dj T106 Ny B a AA OE 22 Z 20 lt p Pe CU z j NRT ik 4 gun apes Nox DA 19 DA 2 f GG Sy i _ SN Py J D 45 Notice Notice Do not damage the cylinder block surface Damage to the cylinder block surface can cause engine failure 14 Remove EN 45680 851 fixture EN 45680 85
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