Cylinder Sleeve Installation 2.4L

Special Tools

For equivalent regional tools, refer to Tools and Equipment.

Caution: 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.

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.

1. Place the NEW cylinder bore sleeve (117) onto the cylinder block.
2. Install EN-45680-851 fixture  (1) with EN-45680-883 cylinder bore sleeve installer over the cylinder bore sleeve (117) and onto the cylinder block. Do not apply downward pressure to the cylinder bore sleeve (117).




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

3. Insert the 4 attachment bolts into the legs of EN-45680-851 fixture  (1).

Caution: Refer to Fastener Caution in the Preface section.

4. Tighten the 4 attachment bolts to 15 N·m (11 lb ft). Do not apply downward pressure to the cylinder bore sleeve (117).



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



6. Align the installation arbor of EN-45680-883 cylinder bore sleeve installer  (1) onto the top of the cylinder bore sleeve (117).



7. Align the pusher block of EN-45680-883 cylinder bore sleeve installer  (2) into the groove of EN-45680-851 fixture  (1).




Caution: Do not use any air powered or electric tools to rotate the threaded shaft of the cylinder bore sleeve installer in the fixture assembly or damage to the cylinder bore sleeve will occur.

8. Using a ratchet, rotate the threaded shaft of EN-45680-883 cylinder bore sleeve installer  (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 EN-45680-883 cylinder bore sleeve installer  (1) to 102 N·m (75 lb ft) 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 EN-4680-851 fixture assembly with EN-45680-883 cylinder bore sleeve installer  (1) from the cylinder block (100).

The EN-45680-861 trim tool assembly  (2) contains or requires the following components to complete 2.4L, 88 mm cylinder sleeve trimming:

Caution: Do not bore or hone the cylinder bore sleeve. The cylinder bore sleeve inside diameter (I.D) is fully machined and honed to size and is optimally finished as shipped. Any attempt to modify this factory-produced sizing and finish with additional boring and honing will lead to engine damage, excessive noise or abnormal oil consumption.

1. After installing the NEW cylinder bore sleeve(s) into the engine block, trim the excess material from the cylinder bore sleeve flange.

Caution: Ensure that all the metal particles are collected in order to prevent internal damage to the engine or bearings.

2. Place EN-45680-884 metal shaving catch plug  (1) into the cylinder bore sleeve to be trimmed. Position the top approximately 3.0 mm (0.12 in) below the top surface of the cylinder bore sleeve.
3. Place additional EN-45680-884 metal shaving catch plugs into all remaining cylinder bore sleeves.




Caution: Installing the metal shaving catch plug deeper than the recommended depth will create a decrease in vacuum system performance. A decrease in vacuum system performance will cause metal shavings to enter the engine and cause engine failure.

Caution: Installing the metal shaving catch plug above the recommended depth will cause damage to the metal shaving catch plug.

4. Ensure that EN-45680-884 metal shaving catch plug  (1) is 3.0 mm (0.12 in) below the top surface of the cylinder bore sleeve.
5. Ensure that the correct bore trimmer pilot and chamfer bit are installed on EN-45680-861 trimmer base assembly :

•	EN-45680-881 chamfer bit , 88 mm sleeve

•	EN-45680-885 trimmer pilot , 88 mm sleeve





Note: Before using the trim tool assembly, the height of the cutting blades must be set to the proper specification. The proper specification is that the cylinder bore sleeve flange must be flush to +0.02 mm (0.0008 in) above the block deck surface.

6. The groove side of the set gage ring (1) on EN-45680-886 gage ring assembly should be positioned upward on a flat surface.




Note: Ensure that the set gage ring on the gage ring assembly surfaces are clean.

7. Carefully position EN-45680-861 trim tool assembly onto the set gage ring.
8. Loosen the shaft collar screw (2).
9. Push the shaft collar (2) downward using the trim tool preloader (1) until the shaft collar is positioned against the top of the flange bearing (3).

Note: Once this procedure is done, it is not necessary to reset the trim tool assembly EN-45680-861 height until the blades are worn, damaged, or replaced.

10. Apply downward pressure on the collar and inner drive shaft using the trim tool preloader (1), then tighten the shaft collar screw to 19 N·m (14 lb ft).



11. Place EN-45680-861 trim tool assembly onto the cylinder to be trimmed with the directional arrow (1) pointing in line with the crankshaft centerline and the front of the block.
12. Install the four EN-45680-864 bolts  (2) into the cylinder head bolt holes in the block and tighten to 20 N·m (15 lb ft).




Caution: For proper tool operation, a drill motor with a 1/2 inch chuck, 1 1/8 hp, 7 amps, triple gear reduction, and a 450-600 RPM rotational speed in a clockwise direction must be used. If the proper drill motor is not used, damage to the cylinder bore sleeve will occur.

13. Fasten EN-45680-866 drive adapter  (1) into the drill chuck.

Caution: Ensure that there are no crimps in the air feed hose or the vacuum hose. Crimps in the hose may cause metal shavings to exit the cutting tool in any direction, causing engine damage.

14. Connect a compressed air supply (75-125 psi) to the male quick connect (3) located on EN-45680-861 trim tool assembly . Turn the compressed air valve (2) to the open position. This starts the venturi vacuum system that will catch the metal shavings.

Note: It should not take longer than 15 seconds to complete the trimming procedure. If it does, the trimming bits must be repositioned to a new cutting surface.

15. Place EN-45680-866 drive adapter and drill assembly (1) vertically onto the drive adapter end of EN-45680-861 trim tool assembly . Do not apply downward force on the drill until full rotational speed has been reached. After reaching full rotational speed, gradually apply downward force until the cutting action is complete in approximately 5 seconds.
16. Remove EN-45680-866 drive adapter  (1) and drill assembly from EN-45680-861 trim tool assembly .
17. Turn off the compressed air valve (2).
18. Remove EN-45680-861 trim tool assembly from the engine block.
19. Remove any material shavings that may be found on the metal shaving catch plug.
20. Wipe the cylinder bore sleeve and surrounding areas free of any powder residue and then remove EN-45680-884 metal shaving catch plug .



21. Install a straight edge (2) on the cylinder block perpendicular to the crankshaft center line.
22. Using a light (1), illuminate the backside of the straight edge.



23. Looking at the front of the straight edge (1), check to see if light is protruding through the bottom of the straight edge and the top of the cylinder bore sleeve flange. If light is present on either side or both sides of the cylinder bore sleeve (2), the cylinder bore sleeve is cut incorrectly and a new cylinder bore sleeve needs to be installed.



24. Looking at the front of the straight edge (1), check to see if light is protruding through the bottom of the straight edge and the top of the cylinder block deck surface. If light is present on both sides of the cylinder block, the cylinder bore sleeve (2) is cut correctly.
25. Proceed to the next bore sleeve to be trimmed repeating steps 10-23 if necessary.