Cylinder Liner Installation

NOTE: The content of this article/image reflects the changes called out by TSB: 04-06-01-022B.

Cylinder Liner Installation

^ Tools Required
- EN-45680400 Cylinder Liner Removal and Installation Kit

Notice: Do not use assembly aids or lubricants on the cylinder bore liner or the cylinder bore block when installing a new cylinder bore liner, or engine damage will occur. These items will not aid in the installation of the new cylinder bore liner.

Notice: Do not chill or heat the cylinder bore liner or the cylinder block when removing or installing a new cylinder bore liner. Chilling or heating the cylinder bore liner or the cylinder block will cause engine damage land will not aid the removal or installation of the new cylinder bore liner.





1. Place the NEW cylinder bore liner (117) onto the cylinder block.
2. Install fixture EN 45680-401/cylinder bore liner installer EN 45680-403 assembly (1) which is part of EN-45680-400, over the cylinder bore liner (117) and onto the cylinder block. Do not apply downward pressure to the cylinder bore liner (117).






Important: Use 4 old cylinder head bolts for the attaching bolts.

3. Insert the 4 attachment bolts into the legs of the fixture EN 45680-401 (1).

Notice: Refer to Fastener Notice in Service Precautions.

4. Tighten the 4 attachment bolts. Do not apply downward pressure to the cylinder bore liner (117).
^ Tighten the 4 attachment bolts to 15 Nm (11 lb ft).





5. Align the bottom of the cylinder bore liner (117) with the cylinder bore of the block (100).





6. Align the installation arbor (1) onto the top of the cylinder bore liner (117).





7. Align the pusher block (2) of cylinder bore liner installer EN 45680-403 into the groove of fixture EN 45680-401 (1).






Notice: Do not use any air powered or electric tools to rotate the threaded shaft of the fixture EN 45680-401/cylinder bore liner installer EN 45680-403 assembly or damage to the cylinder bore liner will occur.

8. Using a ratchet, rotate the threaded shaft of fixture EN 45680-401/cylinder bore liner installer EN 45680-403 assembly (1) in order to install the cylinder bore liner (117) into the engine block (100).
9. Do not completely seat the cylinder bore liner in the block. Leave approximately 1/16 inch of the cylinder bore liner above the surface of the cylinder block.





10. Using a torque wrench, torque the threaded shaft of the fixture EN 45680-401/cylinder bore liner installer EN 45680-403 assembly to 102 Nm (75 lb ft) in order to completely seat the cylinder bore liner in the cylinder block. With the cylinder bore liner properly installed, a minimal portion of the cylinder bore liner flange will protrude above the block deck surface.





11. Remove the fixture EN 45680-401/cylinder bore liner installer EN 45680-403 assembly (1) from the cylinder block (100).