Design/methodology/approach This study has established a comprehensive simulation model of the entire engine operation process and proposed an innovative wear model for engine cylinder liners. It has conducted a thorough investigation into the impact of maintenance factors such as the condition of air filters, the kinematic viscosity of lubricating oil and the fuel supply advance angle on engine performance and cylinder liner wear. Findings Key findings indicate that while a partially blocked air filter can temporarily improve engine performance, it also increases wear. An optimal oil viscosity of 12 mm²/s at 100 °C maximizes engine performance and minimizes wear. Besides, the fuel supply advance angle, with an optimal setting of 30°CA before the top dead center (TDC), significantly influences performance and wear. Originality/value This study introduces a comprehensive simulation model of the engine operation process combined with an innovative wear model for engine cylinder liners. By analyzing the effects of maintenance factors such as air filter condition, oil viscosity and fuel supply advance angle, this research provides practical strategies for enhancing engine performance and predicting lifespan. The findings offer significant insights into optimizing vehicle engine maintenance, contributing to the theoretical foundation and practical approaches for prolonging engine service life. Peer review The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-08-2024-0289/