GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Cobalt 🢒 Engine 🢒 Engine Mechanical - 2.0L 🢒 Cylinder Sleeve Removal

Tools Required

EN-45680-400 Cylinder Sleeve Removal and Installation Kit

    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.

    Notice: Do not damage the crankshaft connecting rod journals or reluctor ring or engine damage will occur.


    Object Number: 1253938 Size: SH
  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 the cylinder bore sleeve puller (1) through the cylinder bore.

    3. Notice: 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 the cylinder bore sleeve puller to the bottom of the cylinder bore sleeve (117).

    4. Object Number: 1253939 Size: SH
  4. Hold the threaded shaft of the cylinder bore sleeve puller upward in order to retain the shoe alignment to the bottom of the cylinder bore sleeve.
  5. Install the fixture (4) onto the threaded shaft of the 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).

    8. Notice: Refer to Fastener Notice in the Preface section.

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

  8. Install and tighten the 4 attaching bolts (2) into the cylinder head bolt holes of the block.

    9. Tighten
    Tighten the bolts to 15 N·m (11 lb ft).


    Object Number: 1253941 Size: SH
  9. Rotate the nut clockwise in order to remove the cylinder bore sleeve.

    10. Object Number: 1253943 Size: SH

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

  10. Remove the fixture, cylinder bore sleeve puller, and the cylinder bore sleeve (117) from the engine block.
  11. Loosen the nut (1) 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 .