Reface Contact Surface of Cylinder Block (Crankcase)

NOTE:
Only machine crankcase contact surface if cylinder liners have been inserted, porous or damaged points exist or an impermissible difference of the flatness in the longitudinal direction is measured. The stock removal at the cylinder head and at the crankcase together must not be more than 0.5 mm.

REMOVAL AND REFINISH
1. Remove pistons
2. Inspect contact surface of crankcase for evenness in longitudinal direction
3. machine contact surface of crankcase together with the timing case cover
- Pay attention to minimum dimensions of crankcase in respect of stock removal
4. Chamfer cylinder bores
5. Test data of crankcase:
- Height of crankcase from center of basic bearing bore (H)
When new: 234.97-235.03 mm
After machining: ≥234.6 mm
- Crankcase
Peak-to-valley height (Rz) upper contact surface: 0.012 mm
Waviness (Wt) upper contact surface: 0.009-0.012 mm
Unevenness of contact surface in transverse direction: 0.030 mm
Chamfer of cylinder bore at contact surface of crankcase: 0.200-1 x 75°

INSTALLATION
- Reverse procedures, noting the following:
Measure piston projection

NOTE: After machining the contact surface of the crankcase, install a repair size cylinder head gasket: 1.85 mm thick, unpressed