Cylinder Sleeve Installation

Cylinder Sleeve Installation

^ Tools Required
- EN 45680-400 Cylinder Sleeve Removal and Installation Kit

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

Notice: 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.





1. Place the NEW cylinder bore sleeve (117) onto the cylinder block.
2. Install fixture EN 45680-401/cylinder bore sleeve installer EN 45680-403 assembly (1) over the cylinder bore sleeve (117) and onto the cylinder block. Do not apply downward pressure to the cylinder bore sleeve (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 Cautions and Notices.

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





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





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





7. Align the pusher block (2) of cylinder bore sleeve 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 sleeve installer EN 45680-403 assembly or damage to the cylinder bore sleeve will occur.





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





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





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