Special Tools

EN-45680-400 Cylinder Sleeve Removal and Installation Kit

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 the cylinder bore sleeve puller EN 45680-402 (1) which is part of EN-45680-400 kit , 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 the cylinder bore sleeve puller EN 45680-402 to the bottom of the cylinder bore sleeve (117).



4. Hold the threaded shaft of the cylinder bore sleeve puller EN 45680-402 upward in order to retain the shoe alignment to the bottom of the cylinder bore sleeve.
5. Install the fixture EN 456850-401 (4) onto the threaded shaft of the cylinder bore sleeve puller EN 456850-402 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. Tighten the bolts to 15 N·m (11 lb ft).



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




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

10. Remove fixture EN 45680-401, cylinder bore sleeve puller EN 45680-402, 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.