Cylinder Sleeve Removal 2.4L

Special Tools

For equivalent regional tools, refer to Tools and Equipment.

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.

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.
2. Install EN-45680-882 cylinder bore sleeve puller  (1) through the cylinder bore.

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.

3. Align the shoe (1) of EN-45680-882 cylinder bore sleeve puller to the bottom of the cylinder bore sleeve (117).



4. Hold the threaded shaft of EN-45680-882 cylinder bore sleeve puller upward in order to retain the shoe alignment to the bottom of the cylinder bore sleeve.
5. Install EN-456850-851 fixture  (4) onto the threaded shaft of EN-456850-882 cylinder bore sleeve puller and the engine block.
6. Install the bearing (3) and the nut (1).
7. Tighten the nut (1) to the bearing (3).

Caution: Refer to Fastener Caution in the Preface section.

Note: Use four old cylinder head bolts for the attaching bolts.

8. Install the 4 attaching bolts (2) into the cylinder head bolt holes of the block and tighten to 15 N·m (11 lb ft).



9. Rotate the nut clockwise in order to remove the cylinder bore sleeve (1).




Caution: Do not damage the cylinder block surface. Damage to the cylinder block surface can cause engine failure.

10. Remove EN-45680-851 fixture , EN-45680-882 cylinder bore sleeve puller , and the cylinder bore sleeve (117) from the engine block.
11. Loosen the nut (1) in order to remove the cylinder bore sleeve (117).
12. Inspect the cylinder bore in the cylinder block for cracks or damage. If cracked or damaged, replace the cylinder block.
13. Inspect the piston, piston rings, and connecting rod for damage. Refer to Piston, Connecting Rod, and Bearing Cleaning and Inspection.