5-101.bk Page 2 Friday, March 17, 2006 11:05 AM [211 DB] CYLINDER BLOCK Cylinder Sleeve Counterbore Universal dial depth gauge PT5025, with a 3-inch stylus extension PT5052-11, is recommended for measuring the counterbore. SPECIAL TOOLS REQUIRED: Counterbore Tool PT2210 Counterbore Cutter Plate PT2210-3A 3. Measure and record the counterbore in four places, 90 degrees apart. Using a depth gauge with a 3-inch extension, mark the shallowest point. Subtract the lowest number from the highest number. This is the minimum amount to be machined for cleanup.
Universal Dial Depth Gauge PT5025 Stylus Extension (3-Inch) PT5052-11 Hex Key Wrench PT2210-14 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. SETTING UP COUNTERBORE TOOL PT2210 WITH CUTTER PLATE PT2210-3A Refer to Figure 5-1. 1. Loosen the two cutter bit hold-down capscrews (9). Install cutter bit (11) into cutter plate PT2210-3A (13) by turning the cutter bit adjuster (10) counterclockwise. Cutter bit face must be facing a clockwise rotation cut.
Use shims to re-establish the correct liner flange height. Shims are available in the following thicknesses: 0.002, 0.003, 0.004, 0.008, 0.010, 0.012 and 0.014 inch. To resurface the cylinder sleeve counterbore area of the cylinder block, use counterbore tool PT2210 with counterbore cutter plate PT2210-3A. Do not tighten the cutter bit hold-down cap (12). 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 counterbore tool onto cylinder block. 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 block to prevent contamination from machining chips. 2. Install the cutter plate on the main shaft (15). Use the large end of hex key wrench PT2210-14 (18) to hold the cutter plate and tighten securely. The hole in the side of the cutter plate accepts the large end of the tool. Do not allow the cutter bit (11) to touch the cylinder sleeve bore wall. Do not cut seats deeper than 4.034 inches (102.464 mm). 1. 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. 2.
Using compressed air, thoroughly remove all debris. Page 5-2 200 BENCH PROCEDURES