1. All machine work may be accomplished on a CNC vertical mill capable of 3-4 axis interpolation with sufficient height to accommodate block height. The bore center distances must be maintained within ±.0005 for sleeve installation to seal properly. (see block specification sheets for dimensions)(See #12 for bore center specs.)
2. All machining must produce a good surface finish and the tolerances must be maintained to assure a quality fit and sleeve seal.
3. Block must be square and perpendicular to machine head. Fixturing should be on main journals provided they are not cracked or distorted. Out of Line 1 and 5, main journals will require main line boring prior to block/sleeve machine work.
4. Final sleeve installation should be accomplished with a brass or aluminum mandrel in cylinders 1 through 4, in that order.
5. After sleeve installation, install a deck plate or head, torque and leave til block is cool.
6. Pressure checking of sleeve seal should be accomplished with a top deck plate and water pump plug as shown in photos on Page 11. The main cap bolts can be used to torque down the top deck plate which should be gasketed with thin rubber sheeting.
7. Finish boring and honing should only be accomplished with a deck plate installed.
8. Field service and singular sleeve replacement is possible and practical by using a slide hammer sleeve puller with the drive mandrel "Flatted" and oriented to provide main web clearance. Sleeves can then be ordered from Darton, by cylinder number.
9. If needed for oversized bores, machine sleeve I.D. out to allow .004-.008 from finished size for cylinder honing.
10. Prior to boring for sleeve installation, bore the existing sleeve to .010 over to finish bore dimension stopping at the main bearing web.
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