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STEP 1
Inspect the liner counterbores for squareness, cracks, and the correct machined depth. Generally, the machined depth is only measured if there has been a problem with protrusion or the counterbore has been machined.
STEP 2
Thoroughly clean the liner and counterbores. Any dirt or other material will prevent the liner from seating properly.
STEP 3
Install and lubricate the liner seals. Seals are lubricated only after they are installed (in order to prevent twisting and rolling when the liner is installed). Slide a small pick beneath the O-ring and move around the liner circumference several times to make sure that the ring is not twisted. Generally, seals are not lubricated with petroleum-based products; this prevents rapid deterioration if the seals are not oil compatible. Antifreeze is often used as an effective lubricant.
STEP 4
Insert the liners into the engine block. Do not force the liners into the block. Instead, use the OEM-prescribed tool to press the liner into the block. Hammering or hitting the flange can dent the flange surface, which causes a leak path. The OEM-prescribed tools will protect the liner flange and sealing surfaces from damage. They can be used to install the liner squarely into the block and, in some cases, clamp the liner into the block.
STEP 5
Clamp the liner in the block with the OEM-prescribed holding or clamping fixture, following the manufacturer’s procedures.
STEP 6
Measure the liner protrusion in three or four places using a dial indicator and sled. Protrusion is measured as the distance between the block deck and a very specific point on the flange; this point varies between manufacturers.
STEP 7
Compare the measured protrusion against the manufacturer’s specification values. Variation from side to side should not exceed 0.001" (0.025 mm). If it does, it is usually due to a piece of debris beneath the flange or a twisted O-ring. Remove, check, and reinstall the liner if the liner variations are excessive from side to side. Install a selective shim beneath any liner flange that sits too low.
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