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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 Removal

Cylinder Sleeve Removal

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.

Special Tools

    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.
    NOTE: Do not damage the crankshaft connecting rod journals or reluctor ring or engine damage will occur.
    Fig 1: View Of Cylinder Bore Liner Puller
    GM1253938Courtesy of GENERAL MOTORS CORP.
  1. If the crankshaft is still installed, rotate the crankshaft so that the counterweight is to the right side and the connecting rod journal is to the left side and not in alignment with the cylinder bore.
  2. Install the cylinder bore sleeve puller EN-45680-882 (1) from EN-45680-880  through the cylinder bore. See Special Tools .
    3. NOTE: Ensure that the shoe is flat against the bottom of the cylinder bore sleeve or damage to the cylinder bore sleeve puller will occur.
  3. Align the shoe (1) of the cylinder bore sleeve puller EN-45680-882 to the bottom of the cylinder bore sleeve (117).
    4. Fig 2: Aligning Cylinder Bore Sleeve Puller
    GM1253939Courtesy of GENERAL MOTORS CORP.
  4. Hold the threaded shaft of the cylinder bore sleeve puller EN-45680-882 upward in order to retain the shoe alignment to the bottom of the cylinder bore sleeve.
  5. Install the fixture EN-456850-851 (4) from EN 45680-850  onto the threaded shaft of the cylinder bore sleeve puller EN-456850-882 and the engine block.
  6. Install the bearing (3) and the nut (1).
  7. Tighten the nut (1) to the bearing (3).
    8. NOTE: Refer to Fastener Notice .
    IMPORTANT: Use four old cylinder head bolts for the attaching bolts.
  8. Install and tighten the 4 attaching bolts (2) into the cylinder head bolt holes of the block.

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

    9. Fig 3: Removing Cylinder Bore Sleeve By Rotating Nut
    GM1253941Courtesy of GENERAL MOTORS CORP.
  9. Rotate the nut clockwise in order to remove the cylinder bore sleeve.
    10. Fig 4: Removing Cylinder Bore Sleeve
    GM1253943Courtesy of GENERAL MOTORS CORP.
    NOTE: Do not damage the cylinder block surface. Damage to the cylinder block surface can cause engine failure.
  10. Remove fixture EN-45680-851, cylinder bore sleeve puller EN-45680-882, and the cylinder bore sleeve (117) from the engine block.
  11. Loosen the nut (1) in order to remove the cylinder bore sleeve (117).
  12. Inspect the cylinder bore in the cylinder block for cracks or damage. If cracked or damaged, replace the cylinder block.
  13. Inspect the piston, piston rings, and connecting rod for damage. Refer to Piston, Connecting Rod, and Bearing Cleaning and Inspection .
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