Hi there, I'm currently in the process of rebuilding my 208GT4 Engine. One aspect of the build relates to the removal and replacement of the piston/bore liners. Removing them, which we thought would be hard or even damaging, turned out to be relatively easy and trouble free. Replacing them, which I expected to be an easier task, has proved to be a big problem as they are breaking when pressing them back in which is puzzling in itself. Any thoughts? I have found a supplier that can supply 6 but the lead time on the 2 extra could be a 6 week wait. I have asked the mechanic to reinstall as many of the remaining surviving liners as possible and hopefully at least 2 of them will survive meaning 6 will be sufficient. Will having old and new liners cause any problems? Do any of you know someone or a supplier that has them in stock, either all 8 or even if just 2 or if they can make them and if so what would be the lead time? Thanks. James
I am more concerned about breaking them. In nearly 40 years I have never once even heard of that being a problem. I install them by hand, unaided in any way by tools so I can't see how they can be broken. If they need to be pressed, something is seriously wrong. They should not fit that way. The factory provides tools that retain the liners during assembly for 2 reasons. If the motor is rotated prior to installation of the heads the drag of the piston rings can lift a liner out of place. Also if you turn the motor over the liners can fall out on the floor (that is when I have seen them break). That being the case you can understand the need to be pressed in place indicates a serious issue. The only time the liners should not just drop in is on a cold day. On those days I place a portable electric heater in front of the block for a while and that problem goes away.
I agree, they should easily go back in place. Try them without the O ring seal, sort of a "dry run". I just rebuilt the diesel engine on my Oliver tractor which uses wet liners just like the 208/308. I pushed the liners in place by hand. I had the same experience on other wet liner engines. If you need to force them in something is VERY wrong. All the wet liner engines that I have worked on have a specific measurement for how far the liner protrudes above the block deck when installed. The protrusion, although slight, insures that the liner will seal to the head gasket. Could your mechanic be trying to force the liner flush with the block's top surface?
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