Operation CHARM: Car repair manuals for everyone.
Manuals through 2025 now available!

Our trusted friends have launched a new website named LEMON, which has newer manuals. It also contains all the CHARM manuals.

LEMON is the spiritual successor to CHARM, I recommend you try it!

Link: lemon-manuals.la or lemon-manuals.org.ua

(Some people have issue connecting. LEMON is investigating. For now, use Firefox or change your DNS server)

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Disassembly






1. Cylinder head assembly.
2. Cylinder head gasket
3. Oil pan
4. Oil pipe and rubber ring
5. Oil strainer and rubber ring
6. Oil gallery
7. Piston and connecting rod assembly





NOTE: Before removing piston and connecting rod assembly, measure thrust clearance.

- Remove any ridge or carbon build up from the top end of the cylinder.





8. Piston ring
- Remove the piston rings with a piston ring expander. Arrange the removed piston rings in the cylinder number order.





9. Piston pin
- Remove the piston pin using a piston pin service set: J-24086-C, or equivalent and piston support with a press.

NOTE: Keep the parts removed from each cylinder separate. All parts must be reinstalled in their original positions. Heating the connecting rod will permit easy removal of the piston pin.

10. Piston
11. Connecting rod