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






REMOVE PISTON RINGS
1. Using a piston ring expander, remove the 2 compression rings.
2. Remove the 2 side rails and oil ring expander by hand.

NOTE: Arrange the piston rings in correct order only.





DISCONNECT CONNECTING ROD FROM PISTON
1. Using a small screwdriver, remove the 2 snap rings.
2. Gradually heat the piston to about 80° C (176° F).





3. Using a plastic-faced hammer and brass bar, lightly tap out the piston pin and remove the connecting rod.

NOTE:
- The piston and pin are a matched set.
- Arrange the pistons, pins, rings, connecting rods and bearings in the correct order.