Mid-Stop Counterbore Cutting

Scene Number: 1127 1000 Scene Title Course Information

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All numbers and specifications listed in this program are used for illustration purposes only.
Current information can be found in the Service Manuals located on QuickServe Online.

Scene Number: 1127 1010 Scene Title Objectives

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At the completion of this course the technician should be capable of measuring cylinder liner
protrusion, measuring the counterbore ledge, and performing the mid-stop counterbore
cutting procedure with the manual cutting tool.

Scene Number: 1127 1020 Scene Title Cylinder Liner Counterbore Machining (Manual Cutting Tool)
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The following section will cover the cylinder liner counterbore machining procedure using the
manual cutting tool.

Scene Number: 1127 1030 Scene Title Preparatory Steps

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Perform the following preparatory steps: drain the cooling system, drain the lubricating oil,
remove the cylinder head, remove the lubricating oil pan, remove the lubricating oil suction
tube, remove the block stiffener plate, remove the piston cooling nozzles and remove the
piston and connecting rod assemblies.

Scene Number: 1127 1040 Scene Title Initial Inspection

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This repair procedure describes the method for machining the cylinder liner counterbore ledge
using the counterbore ledge cutter kit, part number 2892436. The tool is designed to be used
to do light cleanup cuts.
This procedure can be performed in or out of chassis. If performing this procedure out of
chassis, the engine block must be secured to a palette or equivalent to prevent movement and
vibrations. Do not use an engine roll over stand when performing this procedure.
Scene Number: 1127 1050 Scene Title Cylinder Liner Protrusion
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Liner protrusion should be re-checked and verified referring to QuickServe Online. Use depth
gauge, part number 3823495, to measure the liner protrusion at the intake side three times
and average the readings. Measure the liner protrusion at the exhaust side three times and
average the readings. The minimum allowable cylinder liner protrusion is 0.23 mm (0.009 in.)
and the maximum allowable cylinder liner protrusion is 0.36 mm (0.014 in.).
The difference between the lowest cylinder liner and the highest cylinder liner cannot be
greater than 0.102 mm (0.004 in.). The maximum allowable difference between adjacent
cylinders is 0.051 mm (0.002 in.). The measurements must not vary more than 0.0381 mm
(0.0015 in.) within each cylinder.
Cylinder liner shims are available in different thicknesses to adjust cylinder liner protrusion.
The maximum cylinder liner shim thickness is 0.81 mm (0.032 in.).

Scene Number: 1127 1060 Scene Title Cylinder Liner Removal

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Remove the cylinder liner from the cylinder to have the counterbore machined.

Scene Number: 1127 1070 Scene Title Plugging Holes and Chip Catcher Installation
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Cover the crankshaft, plug any oil hole galleries and coolant passages to prevent machining
chips from entering.
Install chip catcher part number 5296519 or part number 5296520 (depending on the block
part number) into the cylinder bore.

Scene Number: 1127 1080 Scene Title Block Preparation

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Make sure the top deck of the cylinder block is clean and free of burrs.
Use a medium grit stone or equivalent to clean the deck of the block and the counterbore
ledge.
Vacuum and remove any debris from the deck of the block, counterbore ledge and cylinder
head capscrew holes.
Visually inspect the counterbore seating area for cracking. If there are any cracks present, the
block must be replaced.

Scene Number: 1127 1090 Scene Title Zero the Counterbore Depth Dial Indicator
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Zero the counterbore depth dial indicator part number 3164438 with the master gauge tool
part number 2892460.
This will set the indicator to the original machining depth of 120 mm (4.724 in.) from the
cylinder deck to the counterbore ledge.
Scene Number: 1127 1100 Scene Title Measure the Counterbore Ledge
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Measure the counterbore ledge in four locations in a crisscross pattern and mark the lowest
point. Subtract the lowest number from the highest number. This is the minimum amount to
be machined for clean-up to make the counterbore ledge even all the way around.

Scene Number: 1127 1110 Scene Title Machining Process - Oil and Base Plate Installation
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Use 30 weight non-detergent oil to lube the counterbore drive unit part number 3163785. Fill
the reservoir with 30 weight oil to maintain lube on the counterbore drive unit while
machining the counterbore ledge.
Assemble the base plate part number 2892423 to the counterbore drive unit with the four hex
key screws provided and torque in a crisscross pattern.

Scene Number: 1127 1120 Scene Title Machining Process - Cutter Plate and Cutter Bit Installation
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Install the cutter plate assembly part number 5296533 to the counterbore drive unit. Use the
cutter plate holder to tighten securely. The hole in the side of the cutter plate accepts the
holder.
Position the cutter bit insert so the tapered edge faces the cutter bit. Install the cutter bit
screw into the center of the cutter bit insert. The cutter bit insert is machined to allow the
cutter bit screw to be fully recessed. Tighten the screw using the provided cutter bit wrench
until the insert is fully seated against the cutter bit. Loosen the screw and tighten it again
until there is no visible air gap around the insert and the bit.
Install the cutter bit part number 5296531 into the cutter plate. The cutter bit must be
installed with the part number facing to the left and the cutting edge facing to the left, as
viewed from the bottom of the cutter plate. Ensure proper installation of the cutter bit as
damage will occur if improperly installed.
Fully retract the cutter bit using the provided hex key wrench. Ensure the cutter bit can
extend and retract freely.

Scene Number: 1127 1130 Scene Title Machining Process - Counterbore Ledge Cutter Unit Installation
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Position the counterbore ledge cutter unit part number 3163785 into the cylinder bore by
backing off the upper depth set collar and lower depth set collar in a counterclockwise
direction. This will allow the counterbore ledge cutting plate to lower and center itself on the
counterbore ledge.
Care should be taken to verify the base plate of the counterbore ledge cutting tool is
positioned flat on the deck surface of the cylinder block.
The cutting plate should be centered into the counterbore ledge with no side to side
movement.
Scene Number: 1127 1140 Scene Title Machining Process - Base Plate Mounting to Block
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Secure the base plate to the cylinder block with the capscrews and washers included with the
tool. Capscrews need to be lubricated with engine oil, installed hand-tight and then torqued
in a crisscross pattern.

Scene Number: 1127 1150 Scene Title Machining Process - T-Handle Installation and Lower Depth Set
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Install the t- handle onto the counterbore ledge cutter unit and adjust the lower depth set
collar in a clockwise rotation 0.127 mm (0.005 in.) [each graduation on the collar is 0.025 mm
(0.001 in.)] to raise the cutter plate off the counterbore ledge and rotate the tool clockwise.
No contact should be made with the counterbore ledge.

Scene Number: 1127 1160 Scene Title Machining Process - Depth Set Collar Installation and Initial
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Raise the counterbore ledge cutter unit up by grasping the t-handle and pulling in an upward
motion.
Install the depth set collar (C) spacer below the lower depth set collar and lower the tool unit
until it makes contact with the depth set collar.
Install a 0.812 mm (0.032 in.) feeler gauge between the counterbore ledge wall and the cutter
bit. This will ensure that the cutter bit does not make contact with the step machined into the
counterbore ledge.
Extend the cutter bit with the hex key wrench installed in the friction screw until the cutter
bit makes contact with the feeler gauge and lock the bit down by tightening the two cutter bit
hold down capscrews with the hex key wrench.

Scene Number: 1127 1170 Scene Title Machining Process - Final Cutter Bit Adjustment
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Position the t-handle so that the long portion of the handle is directly above the cutter bit.
There is no guarantee that the long portion of the handle will line up with the cutter bit.
Rotate the counterbore ledge cutter unit clockwise for 360 degrees, a slight noise may be
heard.
Lower the counterbore ledge cutter unit by adjusting the lower depth set collar in a
counterclockwise rotation, until the cutter bit makes contact with the counterbore ledge.
Raise the counterbore cutter unit 0.127 mm (0.005 in.) by adjusting the lower depth set collar
in a clockwise direction.
Loosen the two cutter bit hold down capscrews with the hex key wrench and extend the
cutter bit until it makes contact with the counterbore ledge wall. Lock the cutter bit.
Scene Number: 1127 1180 Scene Title Machining Process - Counterbore Ledge Clean Up
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Lower the counterbore ledge cutter unit by 0.025 mm (0.001 in.) at a time while rotating the
unit 360 degrees clockwise by adjusting the lower depth set collar in a counterclockwise
rotation until it makes contact with the counterbore ledge.
With the cutter bit making full contact with the counterbore ledge, rotate the counterbore
ledge cutter unit 360 degrees clockwise to clean up the counterbore ledge.
Note: Care should be taken to maintain constant pressure during each 360 degree rotation.
Remove any chips on the counterbore ledge with a vacuum.

Scene Number: 1127 1190 Scene Title Machining Process - Determine Final Cut Depth
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With the counterbore depth dial indicator part number 3164438, measure the depth of the
counterbore ledge. This will determine what the final cut depth will be.

Scene Number: 1127 1200 Scene Title Machining Process - Cutting

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Adjust the upper depth set collar counterclockwise to the final depth cut.
Example: If cutting 0.127 mm (0.005 in.), adjust the upper depth set collar to contact the
lower depth step collar and back it off 0.127 mm (0.005 in.).
Adjust the lower depth set collar counterclockwise 0.025 mm (0.001 in.) at a time until the
final cut is reached.
Rotate the counterbore ledge cutter unit clockwise with the t-handle positioned so the long
portion of the handle is directly above the cutter bit.
Note: Care should be taken to maintain constant pressure during each 360 degree rotation.

Scene Number: 1127 1210 Scene Title Machining Process - Clean and Measurement Check
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The counterbore ledge must be vacuumed out before each measurement.
Note: It is recommend to stop with 0.025 mm (0.001 in.) left to cut and take one final
measurement to verify the cutting depth.

Scene Number: 1127 1220 Scene Title Machining Process - Counterbore Ledge Cutting Unit Removal
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Adjust the lower depth set collar by rotating it clockwise to raise the cutter plate off the
counterbore ledge.
Loosen the two cutter bit hold down capscrews with the hex key wrench and retract the
cutter bit into the cutter plate.
Remove the capscrews that secured the counterbore ledge cutter unit to the deck of the
cylinder block and remove the tool from the engine.
Use a medium grit stone to clean up the leading edge of the counterbore ledge.
Clean any machined chips from the counterbore chip catcher, counterbore ledge and the deck
of the cylinder block.
Scene Number: 1127 1230 Scene Title Machining Process - Final Measurement
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With the counterbore depth dial indicator part number 3164438, measure the depth of the
counterbore ledge and the ledge angle in four places.
The four measurements must not vary more than 0.025 mm (0.001 in.). If the measurements
exceed the specifications, the counterbore ledge must be machined again.

Scene Number: 1127 1240 Scene Title Re-Check Cylinder Liner Protrusion
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Remove the counterbore chip catcher and any oil gallery or coolant passage plugs that were
installed.
Install the appropriate cylinder liner shim.
Install the cylinder liner.
Use depth gauge, part number 3823495, to measure the liner protrusion at the intake side
three times and average the readings. Measure the liner protrusion at the exhaust side three
times and average the readings. If the measurements vary more than 0.0381 mm (0.0015 in.) then
the counterbore will need to be re-machined.
The minimum allowable cylinder liner protrusion is 0.23 mm (0.009 in.) and the maximum
allowable cylinder liner protrusion is 0.36 mm (0.014 in.).
The difference between the lowest cylinder liner and the highest cylinder liner cannot be
greater than 0.102 mm (0.004 in.). The maximum allowable difference between adjacent
cylinders is 0.051 mm (0.002 in.). If the liner protrusion is no longer within specification on
the remaining cylinders, then they will need to be cut accordingly.

Scene Number: 1127 1250 Scene Title Finishing Steps

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Perform the following finishing steps: install the piston and connecting rod assemblies, install
the piston cooling nozzles, install the block stiffener plate, install the oil suction tube, install
the lubricating oil pan, install the cylinder head, fill the engine with clean lubricating oil,
prime the lubricating oil system, fill the cooling system and operate the engine and check for
leaks.

Scene Number: 1127 1260 Scene Title Conclusion

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Scene Number: 1127 1270 Scene Title Assessment

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When measuring the cylinder liner protrusion, the difference between the lowest cylinder
liner and the highest cylinder liner cannot be greater than

Scene Number: 1127 1280 Scene Title Assessment

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True or False: The counterbore ledge should be measured in three locations and the lowest
point should be marked. Subtract the lowest number from the highest number. This is the
minimum amount to be machined for clean-up to make the counterbore ledge even all the way
around.

Scene Number: 1127 1290 Scene Title Assessment

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True or False: The lower depth set collar should be adjusted clockwise 0.127 mm (0.005 in.)
to raise the cutter plate off the counterbore ledge.

Scene Number: 1127 1300 Scene Title Assessment

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How much should the lower depth stop collar be adjusted each time until the final cut is
reached?

Scene Number: 1127 1310 Scene Title Assessment

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What is the maximum cylinder liner protrusion?