Stuck Cylinder Liner (Help!)

[Brockybwoy]

Whilst removing a cylinder head (2.1 litre gasket replacement job) one of the
cylinder liners was stuck to the head and came out past the piston rings
before it loosened ....it's one of the ones nearest the flywheel.
To get it back in requires removing the piston/liner next to the water pump,
however that liner is stuck fast ..I've tried loosening the liner with a
mallet and blunt screwdriver /heat but it won't budge .

I've taken out the piston and cylinder liner on the opposite side .
The "lip" of the stuck liner appears to be protruding a a few mm into the crankcase . I've
filed a notch into a piece of iron bar and thinking of bashing it out from the inside
..something tells me that this may not be a good idea
..Does anyone have experience of this or suggestions ?

[itchyfeet]

yes drift it from the other side ( don't bash it tap it many times with a larger hammer working round evenly it should loosen)
use something soft like wood or nylon on the Barrel
worst case you can replace the barrel

I hope you havent damaged the seal surface in the engine case with that screwdriver

The barrels had to come out anyway to replace the lower seals

pictures?

[CJH]

Barrels can break - even the experienced and well-equipped machine shop that I took my 'scrap heap challenge' of an engine to were unable to remove one of the liners without it breaking. But as Itchy says, you can buy new*.

*Possibly only in sets of four though - I'm not sure.

[silverbullet]

At the first sign of resistance I reach for the propane lamp and warm the cylinder head, they come away easily once expanded a tad.
Bit late for this one I fear.

Ich fahre einen Bulli. Ich hilfe mir selbst...meistens!

[silverbullet]

PS unusual for a barrel to stick in the case, they are quite an loose fit. Any sign of bathroom sealant?

Ich fahre einen Bulli. Ich hilfe mir selbst...meistens!

[itchyfeet]

yes for a Barrel to stick it's either damaged before (maybe a burr) or the seal failed allowing coolant to rust it


Some people are too lazy to change the lower seals when doing the head seals so possible that happened last time and a small weap was happening over time rusting it in.

[Brockybwoy]

thanks everyone for fast replies and usefull suggestions
.Re screwdriver mallet I was trying to loosen cylinder by bashing "lugs" at the top of the barell . No chance of silicone bath sealant as I replaced a cracked piston a few years back.. but as it was the one that went into the barrel that's now stuck, rusted in is a real possibility, though I'm sure I replaced the bottom seal with a new one as I bought had a full set of gaskets/seals. However I stand guilty of laziness and not replacing the seals at the bottom of the other 3 barrels before putting it back together . I've modified "iron bar with notch" tool by melting hot glue stick over the end so it's now got a soft top and less likely to crack the barrel I'll let you know how I get on

[itchyfeet]

Hot melt is too soft it will split off straight away then you will have metal on metal

[itchyfeet]

I'd sacrafice a screwdriver
saw the handle end flat, piece of tube ( copper pipe maybe ) over blade tape the two together

in fact tape the lot up
you don't want bits of platic in the sump if it shatters

[Brockybwoy]

Itchy I've got a fair bit of copper lying around and will definately give it a go... thanks again

[Brockybwoy]

I took Itchies advice and made a copper tipped rust cracking loosening bar . after over an hour of "tapping around" the cylinder liner has still not budged but I notice it's sticknig out a fair bit further than ones on the other side so I'm guessing it rusted in after I took the heads off (back in the spring ) ..guessing I'm going to have to split the crankcase and try to get it out on the bench ..anyone have a single liner for sale ? ( I don't fancy paying £100+ for a full set )

[itchyfeet]

if it's sticking up more than the others it must be moving
you can't assemble the engine with it sticking up

measure and persist a bit longer it could be quicker than splitting the case

try tapping it back down with a piece of wood it often helps to break the rust going in both directions

Call Campershack he has some spare parts for WBX

[itchyfeet]

https://club8090.co.uk/forum/viewtopic.php?f=17&t=152813" onclick="window.open(this.href);return false;
read end of this (Andrew at Campershack )

[Brockybwoy]

Looking again the cylinder liner I'm trying to get out isn't any further out than the others (angle of viewing + wishfull thinking ) to add to my misery the copper tip to my drift bar disintigrated and fallen into crankcase . I've never split a crankcase before but the 4 bolts hidden behind the Liners are on the other side

Thanks for everyones help and suggestions .. I'll be back soon

[Brockybwoy]

Finally got piston Liner out

Gave up on this and offered the job to a mechanic freind of rebuilding engine in exchange for my Missus mint 1975 Suzuki GT185 (4.5K) which he's been trying to get her to sell him for pennies for years.. Came round and repeated my bash it out from other side ,though this time with a (bare) steel bar and it moved a fraction ..said he would come back after he had modifed a "stillie" (plummers pipe spanner) ? to make a puller ..that was weeks ago so looking in garage found my trusty woodworkers steel beam clamps (record) and managed to get them tight enough around the protruding liner to get it to come out after 2-3 light taps with lump hammer.... My mates not going to be pleased though I have got a bit of welding that needs doing... Looking on e-bay GT185's in same condition going for a grand