Sunfire L4-2.2L VIN F (2002)
Cylinder Liner: Technical Service Bulletins
Engine - Cylinder Bore Liner Installation
Bulletin No.: 03-06-01-022A
Date: January 21, 2004
INFORMATION
Subject:
Guidelines for Cylinder Bore Liner/Piston Sleeve Replacement on the L4 Ecotec Engine
Models:
2002-2004 Chevrolet Cavalier
2004 Chevrolet Classic, Malibu
2002-2004 Oldsmoblie Alero
2002-2004 Pontiac Grand Am, Sunfire
with 2.2L Engine (VIN F - RPO L61)
Supercede:
This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 03-06-01-022 (Section 06 - Engine).
Replacement of the cylinder bore liner is now a validated service repair process and an alternative to engine block or engine assembly replacement.
Conditions for engine cylinder bore liner replacement are somewhat difficult to determine and may initially appear as other common customer concerns.
Customer may comment on conditions such as:
^
Engine overheating
^
Engine coolant consumption
^
White smoke from vehicle exhaust
^
Poor heater performance
^
Excessive engine oil consumption
^
Unusual engine knocking noises
All of the above conditions MAY be symptoms of a cylinder bore liner that needs replacement. Cylinder liner replacement determination should be made
AFTER the cylinder head has been removed for inspection. Inspect the engine for the following conditions:
SCUFFED CYLINDER LINER BORE DUE TO THE FOLLOWING:
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Incorrect piston to bore clearance
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Broken or incorrectly installed piston rings
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Incorrectly seated or missing wrist pin clips causing the wrist pin to "walk out"
CRACKED CYLINDER BORE LINER
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Crack in the cylinder bore cylinder liner
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Crack in the flange area cylinder liner
"DROPPED" CYLINDER LINER FLANGE
This "dropped" condition can be determined using a straight edge across the bore liner flange and block deck face. When there is clearance between the
straight edge and the cylinder bore liner flange, the cylinder liner has dropped below the block deck face.
EXCESSIVE CYLINDER BORE WEAR
When the measured cylinder bore diameter exceeds the Service Manual specification, bore liner replacement is the service procedure.
In any of these cases, the cylinder bore liner may be replaced instead of replacing the engine block or engine assembly.
