Machining crankcase contact surface

AR01.40-D-9133A

4.12.96

ENGINES 601.943, 602.980 /982 /984 /985

P01.40-0298-12

Crankcase

A Piston projection

H Height of crankcase from middle of basic bore

H1 Height of crankcase

H2 Height up to middle of basic bearing bore

	Machining
	Only machine cylinder head contact surface if cylinder liners have been inserted, porous or damaged points are present or if an impermissible variation of the flatness in the longitudinal direction is measured. The stock removal at the cylinder head and at the crankcase together must be no more than 0.5 mm. After machining the crankcase contact surface, install a repair cylinder head gasket (1.85 mm thick before being compressed).
1	Measure piston projection	The piston projection (a) for a machined crankcase must not be exceeded	AR03.10-D-7041-01A
			*BE03.10-N-1002-02E
			*BE03.10-N-1001-02E
O2	Remove pistons		AR03.10-D-7021A
			*001589532100
			*343589004000
3	Inspect flatness of crankcase contact surface in longitudinal direction		*BE01.40-N-1005-02D
			*WH58.30-Z-1007-12A
4	Machine contact surface of crankcase together with timing case cover	 Pay attention to the minimum dimensions of the crankcase for stock removal!	*BE01.40-N-1002-02D
			*BE01.40-N-1003-02D
			*BE01.40-N-1004-02D
			*BE01.40-N-1005-02D
5	Chamfer cylinder bores		AR01.40-D-9201-01A
			*BE01.40-N-1006-02D
6	Installing pistons		AR03.10-D-7021A

Inspection data of crankcase

Number	Designation			Engine 601.943


BE01.40-N-1002-02D	Height of crankcase from middle of basic bearing bore (H)	when new	mm	234.95...235.03
		after machining	mm	234.60
		Fig. see		AR01.40-D-9133A
BE01.40-N-1003-02D	Height of crankcase (H1)		mm	299.62
		Fig. see		AR01.40-D-9133A
BE01.40-N-1004-02D	Height up to middle of basic bearing bore (H2)		mm	65.03...65.07
		Fig. see		AR01.40-D-9133A
BE01.40-N-1005-02D	Crankcase	Peak-to-valley height (RZ) of top contact surface	mm	0.012
		Waviness (Wt) of upper contact surface	mm	0.009...0.012
		Unevenness of contact surface in longitudinal direction	mm	0.03
		Unevenness of contact surface in transverse direction	mm	0.03
		Variation of parallelism of top contact surface to bottom in longitudinal direction	mm	0.05
BE01.40-N-1006-02D	Chamfer of cylinder bore at contact surface of crankcase		mm	0.6-175°

Inspection data of crankcase

Number	Designation			Engines 602.980/982/ 983/984/985


BE01.40-N-1002-02D	Height of crankcase from middle of basic bearing bore (H)	when new	mm	234.95...235.03
		after machining	mm	234.60
		Fig. see		AR01.40-D-9133A
BE01.40-N-1003-02D	Height of crankcase (H1)		mm	299.62
		Fig. see		AR01.40-D-9133A
BE01.40-N-1004-02D	Height up to middle of basic bearing bore (H2)		mm	65.02...64.98
		Fig. see		AR01.40-D-9133A
BE01.40-N-1005-02D	Crankcase	Peak-to-valley height (RZ) of top contact surface	mm	0.012
		Waviness (Wt) of upper contact surface	mm	0.009...0.012
		Unevenness of contact surface in longitudinal direction	mm	0.03
		Unevenness of contact surface in transverse direction	mm	0.03
		Variation of parallelism of top contact surface to bottom in longitudinal direction	mm	0.05
BE01.40-N-1006-02D	Chamfer of cylinder bore at contact surface of crankcase		mm	0.2-175°

Test dimensions for pistons

Number	Designation			Engine 601.943	Engines 602.980/982/ 983/984/985


BE03.10-N-1001-02E	Piston projection (a) with new crankcase		mm	0.74...0.96	0.835...1.065
		Fig. see		AR03.10-D-7041-01A	AR03.10-D-7041-01A
BE03.10-N-1002-02E	Piston projection (a) with machined crankcase		mm	0.96...1.16	1.035...1.265
		Fig. see		AR03.10-D-7041-01A	AR03.10-D-7041-01A

343 589 00 40 00

Dial indicator holder

Dial gage

001 589 53 21 00

Commercially available tools

Number	Designation
WH58.30-Z-1007-12A	Steel rule