Cylinder Liner Installation: Notes

Special Tools 

EN-45680-850  Cylinder Sleeve Removal and Installation Kit

For equivalent regional tools, refer to SPECIAL TOOLS (LDK, LHU) .

1. WARNING: 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.
   WARNING: 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.

   Place the NEW cylinder bore sleeve (117) onto the cylinder block.

   Fig 1: Placing Cylinder Bore Sleeve Onto Cylinder Block

   Courtesy of SAAB-SCANIA OF AMERICA, INC.
2. Install the fixture EN-45680-851  fixture and the EN-45680-853  cylinder bore sleeve installer (1) over the cylinder bore sleeve (117) and onto the cylinder block. Do not apply downward pressure to the cylinder bore sleeve (117).
3. NOTE: Use four old cylinder head bolts for the attaching bolts.

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

   Fig 2: Installing EN-45680-853 Cylinder Bore Sleeve Installer

   Courtesy of SAAB-SCANIA OF AMERICA, INC.
4. Refer to FASTENER CAUTION .
   NOTE: Do not apply downward pressure to the cylinder bore sleeve (117).

   Tighten the 4 attachment bolts to 15 Nm (11 lb ft)  .

5. Align the bottom of the cylinder bore sleeve (117) with the cylinder bore of the block (100).
   Fig 3: Aligning Cylinder Bore Sleeve Bottom With Cylinder Bore Block

   Courtesy of SAAB-SCANIA OF AMERICA, INC.
6. Align the installation arbor (1) of the EN-45680-853  cylinder bore sleeve installer onto the top of the cylinder bore sleeve (117).
   Fig 4: Aligning Installation Arbor Of EN-45680-853 Cylinder Bore Sleeve Installer Onto Top Of Cylinder Bore Sleeve

   Courtesy of SAAB-SCANIA OF AMERICA, INC.
7. Align the pusher block (2) of the EN-45680-851  cylinder bore sleeve installer into the groove of fixture (1).
   Fig 5: Aligning Pusher Block Of EN-45680-851 Cylinder Bore Sleeve Installer Into Groove Of Fixture

   Courtesy of SAAB-SCANIA OF AMERICA, INC.
8. WARNING: 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.

   Using a ratchet, rotate the threaded shaft of the EN-45680-853 (1)  cylinder bore sleeve installer in order to install the cylinder bore sleeve (117) into the engine block (100).

   Fig 6: Installing Cylinder Bore Sleeve Into Engine Block

   Courtesy of SAAB-SCANIA OF AMERICA, INC.
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-45680-851  fixture assembly (1) to 102 Nm (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.
    Fig 7: Identifying EN-45680-851 Fixture Assembly

    Courtesy of SAAB-SCANIA OF AMERICA, INC.
11. Remove the EN-45680-851  fixture assembly with the EN-45680-853 (1)  cylinder bore sleeve installer from the cylinder block (100).
    Fig 8: Removing Cylinder Bore Sleeve Installer From Cylinder Block

    Courtesy of SAAB-SCANIA OF AMERICA, INC.