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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1629 (Engine Mechanical - 2.4L) >> Repair Instructions - On Vehicle >> Cylinder Sleeve Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2009 Saturn Vue. However, it is still accessible from the selected car via links, so may be relevant.
    CAUTION: 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.
    CAUTION: Do not damage the crankshaft connecting rod journals or reluctor ring or engine damage will occur.
    Fig 1: View Of Cylinder Bore Sleeve Puller
    GM1333588Courtesy of GENERAL MOTORS CORP.
  1. Remove the piston and connecting rod. Refer to Piston, Connecting Rod, and Bearing Replacement .
  2. Inspect the condition of the piston. Refer to Piston, Connecting Rod, and Bearing Cleaning and Inspection .
  3. 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.
  4. Install the EN 45680-882 cylinder bore sleeve puller (1) through the cylinder bore.
    5. CAUTION: Ensure that the shoe is flat against the bottom of the cylinder bore sleeve or damage to the cylinder bore sleeve puller will occur.
  5. Align the shoe (1) of the EN 45680-882 cylinder bore sleeve puller to the bottom of the cylinder bore sleeve (2).
    6. Fig 2: Aligning Cylinder Bore Sleeve Puller
    GM1253939Courtesy of GENERAL MOTORS CORP.
  6. Hold the threaded shaft of the EN 45680-882 cylinder bore sleeve puller upward in order to retain the shoe alignment to the bottom of the cylinder bore sleeve.
  7. Install the EN 456850-881 fixture (4) onto the threaded shaft of the EN 456850-882 cylinder bore sleeve puller and the engine block.
  8. Install the bearing (3) and the nut (1).
  9. Tighten the nut (1) to the bearing (3).
    10. CAUTION: Refer to Fastener Caution .
    NOTE: Use 4 old cylinder head bolts for the attaching bolts.
  10. Install and tighten the 4 attaching bolts (2) into the cylinder head bolt holes of the block. Tighten the bolts to 15 N.m (11 lb ft).
    11. Fig 3: Identifying Cylinder Bore Sleeve Puller Nut
    GM1333489Courtesy of GENERAL MOTORS CORP.
  11. Rotate the nut clockwise in order to remove the cylinder bore liner.
    12. Fig 4: Cylinder Bore Sleeve
    GM1333497Courtesy of GENERAL MOTORS CORP.
    CAUTION: Do not damage the cylinder block surface. Damage to the cylinder block surface can cause engine failure.
  12. Remove EN 45680-881 fixture, EN 45680-882 cylinder bore sleeve puller, and the cylinder bore sleeve from the engine block.
  13. Inspect the cylinder bore in the cylinder block for cracks or damage. If cracked or damaged, replace the cylinder block.
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