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Cylinder Liners: Installation

WARNING: This page is about a different car, the 2005 Jeep Liberty. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: Cleanliness can not be over emphasized enough when cleaning the cylinder liner to engine block mating surfaces. Failure to do so will result in the wrong protrusion reading. Only one shim per sleeve fitting. DO NOT stack or reuse shims.
NOTE: When installing liners for protrusion measurement, remove all O-rings and discard original shim.
  1. Carefully clean liner and engine block, and degrease the engine block deck where it comes into contact with the liners. Install the liners in the engine block as shown, rotating them back and forth by 45° in order to guarantee correct positioning. See Fig 1.
    Fig 1: LINER INSTALLATION
    GC0026197Courtesy of DAIMLERCHRYSLER CORP.
    1 - CYLINDER LINER
    2 - SHIMS
    3 - O-RINGS
    4 - BLOCK LEDGE
    5 - ENGINE BLOCK
    NOTE: All Measurements Must Be Taken On the High Pressure Pump Side.
  2. Measure the liner recess relative to block deck with dial indicator VM.1013 mounted on a special tool VM.1010 A. Zero dial gauge on block deck.
    NOTE: The cylinder liner reading will actually be a negative number.
  3. Move dial gauge to cylinder liner edge record reading on dial gauge. The reading should be negative.
  4. Remove liner and special tools.
  5. Then select the correct shim thickness to give proper protrusion (0.00 - 0.05 mm).
    NOTE: The O-rings are used toward the bottom of the liner. Each liner has three O-rings that prevent coolant and engine oil from mixing. The brown (bottom) O-ring is an oil seal and the two black (top) O-rings are water seals.
  6. Fit the proper shim, and the O-rings, onto the liner.
  7. Lubricate the lower liner location in the block.
    CAUTION: When installing special tool VM.1075, make sure the tool does not rotate when tightening and damage the cylinder liner. DO NOT rotate the engine with out special tool VM.1075 in position.
  8. Fit the liners in the crankcase making sure that the shim is positioned correctly in the seat. Lock the liners in position using special tool (VM.1076) and bolts tightened to 50 N.m (37 ft. lbs.). See Fig 2.
    Fig 2: LINER CLAMP LOCATION
    GC0026196Courtesy of DAIMLERCHRYSLER CORP.
    1 - ENGINE BLOCK
    2 - LINER RETAINER VM.1076
    3 - CYLINDER LINER
  9. Recheck the liner protrusion. It should be 0.00 - 0.05 mm.
  10. Reassemble engine.
  11. Install engine in vehicle.
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