Kades nailed it- - - - -leave a step at the bottom of the bore by stopping the cut about 1/8" before it goes out the bottom, then bore the hole about .002" smaller than the average outside diameter of the sleeve. The cylinder head holds the sleeve down from the top, so it can't move. I don't bother with heating or cooling, just drive the sleeve into the block with a heavy steel plate on top of it and use a BFH to tap it into place. I believe the shock of driving a sleeve in helps it to self-align with the hole as it goes in. Using a press can crack a block if the sleeve gets into a bind. I cut the sleeve a few thousandths taller than the bored hole, then either draw-file it flush with the top of the block or use a square tool bit on the boring bar to cut it flush. I make a mark with soapstone around the top of the block and stop cutting just as the tool begins to scrape the mark away. Finish with a draw-file. This prevents undercutting the top of the block which can cause a head gasket leak. The ID of the sleeve is smaller than a standard bore, so it can be bored and honed to the exact size to fit the pistons. I stop boring .002" below the desired diameter, and finish the sizing process with a rigid hone to eliminate tooling marks. The final few passes with the hone are done with a rapid up/down motion to create a 60 degree cross-hatch pattern for ring seating.
No, it's definitely not just a matter of boring a hole and dropping a sleeve into it. When the sleeve is installed the right way, the material is better than the original block alloy, and combustion heat transfers to the coolant exactly like a cylinder without a sleeve.
Sleeves for Cummins and Detroit Diesel engines are a close slip fit in the block and have a flange at the top so the cylinder head sandwiches the sleeve between the head and the block counterbore. Cummins uses shims to set the cylinder liner a couple of thousandths above the top of the block for proper gasket sealing. Those sleeves get changed during an overhaul, along with new pistons, so the bore is always standard- - -no such thing as an oversize piston, and no wear to the block. The Chevy Vega with the aluminum block and the cast iron plated pistons was routinely retrofitted with a flanged sleeve and normal aluminum pistons, and cutting the counterbore into the top of the block was a very tricky process. Fun stuff!
Jerry
