Cylinder Bore Liner Removal/Installation
Cylinder Bore Liner RemovalNotice:
Be careful not to damage the crankshaft connecting rod journals or reluctor ring.
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.
Important:
Use four old cylinder head bolts for the attaching bolts.
2. Install EN 45680-851 (2) to the cylinder block while installing the EN 45680-852 (1) through the cylinder bore.
Notice:
Be sure the shoe is flat against the bottom of the cylinder bore liner or damage to the EN 45680-852 will occur.
3. Align the shoe (1) of EN 45680-852 to the bottom of the cylinder bore liner (117).
4. Hold the threaded shaft upward in order to retain the shoe alignment to the bottom of the cylinder bore liner. Tighten the nut (1) to the bearing (3).
5. 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).
6. Rotate the nut clockwise in order to remove the cylinder bore liner.
Notice:
Be careful not to damage the cylinder block surface. Damage to the cylinder block surface can cause engine failure.
7. Remove EN 45680-851, EN 45680-852 and the cylinder bore liner (117) from the engine block.
8. Loosen the nut (1) in order to remove the cylinder bore liner (117).
Cylinder Bore Liner Installation
1. Place the NEW cylinder bore liner (117) onto the cylinder block.
2. Install EN 45680-851/EN 45680-853 assembly (1) 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 EN 45680-851 (1).
4. Tighten the 4 attachment bolts. Do not apply downward pressure to the cylinder bore liner (117).
Tighten
Tighten the 4 attachment bolts to 15 N.m (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 EN 45680-853 into the groove of EN 45680-851 (1).
Notice:
Do not use any air or electric tools to rotate the threaded shaft of the EN 45680-851/EN 45680-853 assembly or damage to the cylinder bore liner will occur.
8. Using a ratchet rotate the threaded shaft of EN 45680-851/EN 45680-853 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 assembly above the surface of the cylinder block.
10. Using a torque wrench, the cylinder bore liner can be completely seated in place when the threaded shaft is torqued to 102 N.m (75 lb ft). With the liner properly installed, a minimal portion of the liner flange will protrude above the block deck surface.
11. Remove the EN 45680-851/EN 45680-853 assembly (1) from the cylinder block (100).