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2.3L ('02-'11) 2004 2.3L cylinder sleeve/liner


clwhitt

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I have a 2004 2.3 DOHC liter engine that had a piston fail, scoring the cylinder. I took the block to a local machine shop to have it bored/sleeved, or whatever it needed. It's been almost two months. The shop ordered a sleeve, expecting something on the order of 90/1000 (3/32?), and got a sleeve that was 100/1000 (give me a little leeway on the numbers, he was rattling them off fast). He sent it back figuring it was mis-boxed. Three sleeves later he's still getting the thicker sleeve, which he still thinks is too thick. He's also not finding satisfaction on why there seems to be a discrepancy and is hesitant to bore out the block until he's sure of the answer.
I'd like to get the block back. What are the experiences of members here on sleeving a block back to stock? What are the correct dimensions? Googling it I'm finding Darton sleeves for what seem to be builds for more HP, not so much just a stock fix. Who has done this before? What information can you share with me to help me get my block back?

Thanks,
Chuck
 


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DCman

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I think you just need to be a little more patient, if possible.
You've got a winner in that machinist. Not everyone would check the new part before installing it and then question what was going on when it fell out of spec.
The guy knows what he's doing. He'll get it sleeved, just give him some time.
 

franklin2

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Sleeving a block is expensive in my neck of the woods. Is that engine hard to find? A good used one would be as cheap or cheaper than getting that one cylinder sleeved wouldn't it?
 

Dirtman

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Sleeving a block is expensive in my neck of the woods. Is that engine hard to find? A good used one would be as cheap or cheaper than getting that one piston sleeved wouldn't it?
It's an aluminum engine, it already has sleeves. It's a replacement part not a full blown machining job like on an iron block that never had sleeves. Still requires some work but not like you're thinking.
 

franklin2

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It's not o-ringed and presses out like some engines is it? You still have to cut it out and press/loctite the replacement in place?
 

tomw

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Pretty sure it has no O-rings, and is not designed to have the sleeve replaced as a normal course of action.

I am not a pro, but expect that it will need boring to a specific diameter, and pressing in of a chilled sleeve designed to fit that diameter.
The sleeve supplier should have specified the finished ID of the bored sleeve remaining in the block(likely not all would be removed, just bored to spec), and the procedure for installation, including temperature, lubricant as needed, and so on. The installed sleeve would then be mic'd and a finish bore done as needed, or possibly just honing. I am not a machinist.
tom
 

franklin2

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Pretty sure it has no O-rings, and is not designed to have the sleeve replaced as a normal course of action.

I am not a pro, but expect that it will need boring to a specific diameter, and pressing in of a chilled sleeve designed to fit that diameter.
The sleeve supplier should have specified the finished ID of the bored sleeve remaining in the block(likely not all would be removed, just bored to spec), and the procedure for installation, including temperature, lubricant as needed, and so on. The installed sleeve would then be mic'd and a finish bore done as needed, or possibly just honing. I am not a machinist.
tom
That's what I am thinking and that sort of work is not cheap. I don't know where he lives, but I looked up that engine on www.car-part.com and in my area I can get a complete used engine for around $1000.
 

Dirtman

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I've never done one on a 2.3 but have replaced sleeves on other engines. Usually its press out the old, press in the new, and the one's I've used came with a factory bore, you just had to hone it to true it to size after being installed because they do get tweaked a tad after being pressed in. It's not at all hard work and can usually be done with the engine still in the truck.
If he's rebuilding the engine I highly doubt they are charging much more for a sleeve and in the end you have a factory spec new engine not "used".

Now sleeving an iron block on the other hand is insane and hardly worth it unless it's some magical or rare engine like a 428 sohc...
 

racsan

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Sounds similar to a diesel, didn’t realize its being done with gas automotive engines.
 

DCman

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I don't think they do, racsan.
 


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