Page 190
REPAIR INSTRUCTIONS, PART 1
Cylinder Sleeve Counterbore
[211 DB]
INSPECTION AND REPAIR
If the cylinder block deck is resurfaced, the
cylinder sleeve counterbore depth must be recut
to specification. If the cylinder block deck was not
resurfaced but cylinder sleeve counterbore
surface shows excessive pitting or erosion, recut
the counterbore as required.
Use shims to re-establish the correct liner flange
height. Shims are available in the following
thicknesses: 0.002, 0.003, 0.004, 0.010, 0.012,
0.014, 0.020, 0.031 and 0.042 inch thicknesses,
and are to be used as a single shim repair
whenever possible.
If it is necessary to use more than a single shim,
use the fewest shims possible. Also because very
thin shims can be displaced, avoid the use of
0.002, 0.003 and 0.004 shim sizes whenever
possible.
Due to manufacturing tolerance differences, all
shims should be measured to determine their
actual shim thickness dimension before recutting
the sleeve seat.
To resurface the cylinder sleeve counterbore
area of the cylinder block, use counterbore tool
PT2210 with counterbore cutter plate
PT2210-3A.
This procedure can be performed either in or out
of the chassis. If performing the procedure in the
chassis, be sure to cover the crankshaft and any
holes in the cylinder block to prevent
contamination from machining chips.
1. Thoroughly clean and inspect the sleeve
seating surface on the cylinder block
counterbore flange. Visually identify the
counterbore flange that has the most severe
pitting and recut it first to determine if the
block will be within the specified recut limits.
Do not cut seats deeper than 4.040 inches
(102.616 mm). If the maximum recut dimension is
reached and visible pitting remains, the pitting is
acceptable as long as there is not a complete
leak path all the way across the cylinder block
sleeve seat surface.
2. Make sure that the top of the deck is clean
and free of burrs. Use a finish mill file and
crocus cloth, if necessary, to create a
smooth, flat surface for positioning the tool.
3. Using compressed air, thoroughly remove all
debris.
Universal dial depth gauge PT5025, with a
three-inch stylus extension PT5025-11, is
recommended for measuring the counterbore.
4. Measure and record the counterbore in four
places, 90 degrees apart. Using a depth
gauge with a three-inch extension, mark the
shallowest point. Subtract the lowest
number from the highest number. This is the
minimum amount to be machined for
cleanup. Additional machining may be
required depending on the size of any
remaining pits.
SETTING UP COUNTERBORE TOOL PT2210
WITH CUTTER PLATE PT2210-3A
Refer to Figure 190.
1. Loosen the two cutter bit hold-down
capscrews. Install the cutter bit into the
cutter plate PT2210-3A by turning the cutter
bit adjuster counterclockwise. The cutter bit
face must be positioned for a clockwise
rotation cut.
Do not tighten the cutter bit hold-down cap.
The cutter point should not extend beyond the
outer edge of the cutter plate. If the cutter bit
does stick out, damage to the bit will occur when
installing the counterbore tool on the cylinder
block.
5-111.bk Page 190 Monday, July 10, 2006 2:26 PM
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