2-16. CYLINDER BLOCK REPAIR (Contd)
Installation of cylinder sleeves.
Do not use cylinder sleeves to repair a cracked engine block.
Cylinders that still show damage or wear after being honed to a
maximum oversize of 0.030 in. (0.762 mm) will require sleeves.
a. Identify cylinders that require sleeves.
b. Using micrometer, measure outside diameter of cylinder sleeve (1).
Before using any type of boring bar, the top of the cylinder block
should be filed off to remove any dirt or burrs. This is very
important. If not checked, the boring bar may be tilted, which
would result in the rebored cylinder wall not being at right
angle to crankshaft.
The cylinder must be bored to within 0.125 in. (3.18 mm) of the
rod relief in the bottom of the cylinder. Ensure the depth of the
bore does not exceed the length of the sleeve. Ensure to cut the
bottom of the bore square. This will provide a stop, or ledge, for
the sleeve to bottom out on.
c. Using cylinder boring machine, bore cylinder (2) to diameter of sleeve (1) less 0.002 to 0.003 in.
(0.051 to 0.076 mm) to create an interference fit between sleeve (1) and cylinder (2).
Store the sleeve in a freezer at a temperature of 28 to 30°F (-2.2 to
-1.1°C) for several hours before installing it into the engine block.
d. Apply bead of high temperature sealing compound to top and bottom of cylinder (2) bore. Press
frozen sleeve (1) into cylinder (2) until it bottoms out on ledge at bottom of cylinder (2) bore.
e. Remove any excess sleeve material protruding above the head deck surface (4). Finish the
sleeve (1) flush with deck of block (3), taking care not to damage deck surface (4).
Using cylinder boring machine, bore the sleeved cylinder (1) to appropriate piston size.
g. Finish cylinder surface (refer to para. 2-16.d.1).