Operation CHARM: Car repair manuals for everyone.

General

Displacement (CID) 6.81 (415)
No. Cylinder 10
Bore/stroke 90.215/105.8 mm
Fire order 1-6-5-10-2-7-3-8-4-9
Cylinder Head/Valve Train Combustion chamber volume 52.6 - 51.6 cc
Valve seat width-intake 2.1 - 1.9 mm
Valve seat width-exhaust 2.1 -1.9 mm
Valve seat angle 45.00-44.50 degrees
Valve seat runout (T.I.R.) 0.025 mm
Valve Arrangement (Front to Rear) Valve stem guide clearance intake 0.069-0.020 mm
exhaust 0.095-0.045 mm
Valve head diameter intake 44.63-44.37 mm
exhaust 34.12-33.88 mm
Valve face runout (limit) 0.05 mm
Valve face angle 45.75-45.25 degrees
Valve stem diameter intake 6.995-6.975 mm
exhaust 6.970-6.949 mm
Valve stem diameter (list oversizes) intake N/a
exhaust N/a
Valve spring compression pressure Intake (N @ spec. length) 667.3 N @ 28.02 mm
Exhaust (N @ spec. length) 667.3 N @ 28.02 mm
Valve spring free length intake 50.2 mm
exhaust 50.2 mm
Valve spring installed pressure N @? spec. length intake 289.1 N @ 40.01 mm
exhaust 289.1 N @ 40.01 mm
Valve springs installed pressure N @ spec. length -service limit intake 274.6 mm @ 40.01 mm
exhaust 274.6 mm @ 40.01 mm
Valve springs-out of square limit intake 2.5 degrees
exhaust 2.5 degrees
Valve guide inside diameter 7.044-7.015 mm
Camshaft Lobe lift intake 6.58077 mm
exhaust 6.58551 mm
Lobe lift-allowable lift loss 0
Valve lift @ zero lash intake 12.00 mm
exhaust 12.00 mm
Camshaft end play 0.25-0.188 mm
End play service limit 0.025-0.188 mm
Journal to bearing clearance 0.076 - 0.025 mm
Clearance service limit Journal diameters 26.962-26.936 mm
Journal inside diameter(cap 27.012-26.987 mm assembled)
Camshaft runout: full indicator measurement on all journals when supported on front and rear journals. 0.09 mm (5 places)
Cylinder bore diameter grade 1 90.200-90.210 mm
grade 2 90.210-90.220 mm
grade 3 90.220-90.230 mm
Piston Piston diameter (grade 2) at right angle to pin bore 90.180 +- 0.005 mm
Piston to bore clearance (-0.005) to +0.025 mm
Pin bore diameter (piston) 22.008-22.014 mm
Pin diameter 22.0005-22.0030 mm
Clearance (neg. Or pos.) 0.01395-0.005 mm
Pin bore diameter (rod) 22.012-22.024 mm
Clearance 0.009-0.0235 mm
Ring groove width top 1.503-1.505 mm
intermediate 1.502-1.504 mm
Oil control 3.030-3.050 mm
Piston ring gap top 0.13-0.28 mm
intermediate 0.25-0.40 mm
Oil control 0.15-0.65 mm
Crankshaft Main bearing journal diameter 67.482-67.504
maximum out-of-round sections 0.0075 mm between cross.
maximum taper (straightness) 0.004 mm
Runout: firm of center journals when located on front and rear journal 0.05 mm 3 places
Clearance-crankshaft journal to main bearing clearance 0.048-0.024 mm
Connecting rod journal diameter 53.003-52.983 mm
Maximum out-of-round 0.0075 mm between cross sections
maximum taper 0.004 mm
Crankshaft end play 0.075-0.377
Connecting Rod Big end journal inside diameter with assembled liners 53.049-53.027 mm
Rod bearing to journal clearance 0.064-0.026 mm
Pin bore diameter (rod) 22.024-22.012 mm
Balance Shaft System Balance shaft journal diameter 26.962 - 26.936 mm
Clearance-balance shaft journal to cylinder head 0.076 - 0.025 mm
Cylinder head B/S journal diameter 27.012 - 26.987 mm
Gear backlash 0.0076 - 0.1295 mm
Balance shaft endplay 0.04 - 0.18 mm
Rod length (centerline bore-to-bore) 169.1 mm
Alignment bore-to-bore max. Twist +/- 0.05 mm
bore-to-bore max. Bend +/- 0.038 mm
Side play (as assembled to crank) standard play 0.410 + 0.26 mm
max play 0.670 mm