The supporting flange for a wet liner in a diesel engine was analyzed. The results show that stresses can vary as much due to manufacturing tolerance bands as due to major dimensional changes in the joint area. Guidelines have been developed for selecting fillet radii and for the size and shape of the contact area between the liner and block. Further, the paper shows that analytical methods can be used to aid the designer in determining not only the basic dimensions but also the tolerances. The analytical techniques also allow “trial and error” comparison of slight variations in design more easily than by testing. Detail evaluation can be accomplished with this analytical approach that is difficult, if not impossible, to accomplish with available experimental methods.