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Home >> Chevrolet >> 2006 >> Cobalt LTZ >> Repair and Diagnosis >> External Pages >> Different car >> Section 791 (Engine Mechanical - 2.4L) >> Repair Instructions - Off Vehicle >> Cylinder Sleeve Installation >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2008 Pontiac G5 and 2008 Chevrolet Cobalt. 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.
    Fig 1: View Of Cylinder Bore Sleeve Fixture
    GM1253945Courtesy of GENERAL MOTORS CORP.
  1. Place the NEW cylinder bore sleeve (117) onto the cylinder block.
  2. Install the fixture EN-45680-851 (1) from EN 45680-850  with the cylinder bore sleeve installer EN-45680-883 from EN-45680-880  over the cylinder bore sleeve (117) and onto the cylinder block. See Special Tools . Do not apply downward pressure to the cylinder bore sleeve (117).
    3. Fig 2: Installing Cylinder Bore Sleeve Puller Attachment Bolts
    GM1253946Courtesy of GENERAL MOTORS CORP.
    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).
    4. NOTE: Refer to Fastener Notice .
  4. Tighten the 4 attachment bolts. Do not apply downward pressure to the cylinder bore sleeve (117).

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

    5. Fig 3: View Of Proper Liner Alignment
    GM1253949Courtesy of GENERAL MOTORS CORP.
  5. Align the bottom of the cylinder bore sleeve (117) with the cylinder bore of the block (100).
    6. Fig 4: View Of Installation Arbor
    GM1253954Courtesy of GENERAL MOTORS CORP.
  6. Align the installation arbor of the cylinder bore sleeve installer EN-45680-883 (1) from EN-45680-880  onto the top of the cylinder bore sleeve (117). See Special Tools .
    7. Fig 5: View Of Pusher Block
    GM1253956Courtesy of GENERAL MOTORS CORP.
  7. Align the pusher block of the cylinder bore sleeve installer EN-45680-883 (2) into the groove of fixture EN-45680-851 (1).
    8. Fig 6: Installing Cylinder Bore Sleeve Into Engine Block Using Tool
    GM1253957Courtesy of GENERAL MOTORS CORP.
    NOTE: Do not use any air powered or electric tools to rotate the threaded shaft of the cylinder bore sleeve installer in the fixture assembly or damage to the cylinder bore sleeve will occur.
  8. Using a ratchet, rotate the threaded shaft of the cylinder bore sleeve installer EN-45680-883 (1) in order to install the cylinder bore sleeve (117) into the engine block (100).
  9. 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.
    10. Fig 7: Seating Cylinder Bore Sleeve Completely Using Tool
    GM1253960Courtesy of GENERAL MOTORS CORP.
  10. Using a torque wrench, torque the threaded shaft to 102 N.m (75 lb ft) 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.
    11. Fig 8: View Of Service Tool Assembly
    GM1253963Courtesy of GENERAL MOTORS CORP.
  11. Remove the fixture assembly EN-4680-851 with the cylinder bore sleeve installer EN-45680-883 (1) from the cylinder block (100).
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