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Home >> Chevrolet >> 2001 >> Cavalier LS, 2.2 4 >> Repair and Diagnosis >> External Pages >> Different car >> Section 236 (Engine Mechanical - 2.2L (L61)) >> Repair Instructions >> On-Vehicle Repair Instructions >> Cylinder Sleeve Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 Pontiac Sunfire and 2004 Chevrolet Cavalier. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: 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.
NOTE: 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.
  1. Place the NEW cylinder bore sleeve onto the cylinder block.
    Fig 1: Cylinder Bore Sleeve
    GM1333497Courtesy of GENERAL MOTORS CORP.
  2. Install fixture EN 45680-851  /cylinder bore sleeve installer EN 45680-853  assembly over the cylinder bore sleeve and onto the cylinder block. Do not apply downward pressure to the cylinder bore sleeve.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
    IMPORTANT: Use 4 old cylinder head bolts for the attaching bolts.
  3. Insert the 4 attachment bolts into the legs of the fixture EN 45680-851  (1). Do not apply downward pressure to the cylinder bore sleeve (2).

    Tighten:  Tighten the 4 attachment bolts to 15 N.m (11 lb ft).

    Fig 2: View Of Cylinder Bore Sleeve Installer
    GM1355764Courtesy of GENERAL MOTORS CORP.
  4. Align the bottom of the cylinder bore sleeve (1) with the cylinder bore of the block (2).
    Fig 3: Aligning Cylinder Bore Sleeve
    GM1355961Courtesy of GENERAL MOTORS CORP.
  5. Align the installation arbor (1) onto the top of the cylinder bore sleeve (2).
    6. Fig 4: Aligning Installation Arbor
    GM1355962Courtesy of GENERAL MOTORS CORP.
  6. Align the pusher block (2) of cylinder bore sleeve installer EN 45680-853  into the groove of fixture EN 45680-851  (1).
    Fig 5: View Of Pusher Block
    GM1253956Courtesy of GENERAL MOTORS CORP.
    NOTE: Do not use any air powered or electric tools to rotate the threaded shaft of the fixture EN 45680-851  /cylinder bore liner installer EN 45680-853  assembly or damage to the cylinder bore liner will occur.
  7. Using a ratchet, rotate the threaded shaft of fixture EN 45680-851  /cylinder bore sleeve installer EN 45680-853  assembly in order to install the cylinder bore sleeve into the engine block.
    Fig 6: View Of Cylinder Bore Sleeve Installer Assembly
    GM1333492Courtesy of GENERAL MOTORS CORP.
  8. Do not completely seat the cylinder bore sleeve in the block. Leave approximately 1/16 inch of the cylinder bore sleeve above the surface of the cylinder block.
  9. Using a torque wrench, torque the threaded shaft of the fixture EN 45680-851  /cylinder bore sleeve installer EN 45680-853  assembly to 102 N.m (75 lb ft) in order to completely seat the cylinder bore sleeve in the cylinder block. With the cylinder bore sleeve properly installed, a minimal portion of the cylinder bore sleeve flange will protrude above the block deck surface.
    Fig 7: Seating Cylinder Bore Sleeve Completely Using Tool
    GM1253960Courtesy of GENERAL MOTORS CORP.
  10. Remove the fixture EN 45680-851  /cylinder bore sleeve installer EN 45680-853  assembly (1) from the cylinder block (2).
    Fig 8: Identifying Cylinder Bore Sleeve Installer Assembly
    GM1355963Courtesy of GENERAL MOTORS CORP.
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