Where can I get cylinder liners for a 617 engine (81 300sd) that has non standard sized pistons (90.86mm)? No one seems to have anything but standard sized liners. Any help appreciated

These are not sized liners as are found in some of the wet sleeve industrial diesels. They are simply dry liners that are put in place, bored to fit the piston, even if a standard size piston is used, and then topped even with the deck. It is a machine shop operation to replace them.

If you have used pistons it is best, IMHO, to replace the pistons and bore to the next oversize. These pistons are HIGHLY stressed and not a good part to reuse in this application. Used pistons are commonly reused in gas engines with great success, but they do not see the same life as your diesel with a compression ratio in excess of 20:1 and recieving the impact loading that is presented by diesel combustion. This impact loading is so severe that you can even hear it in the form of diesel knock.

If your engine is already bored to the last oversize, then buy new standard pistons, resleeve the block and bore to fit the new pistons.

Good luck,