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)

Or, hide this message: temporarily or permanently

Service Specifications

Maximum head to block warpage 0.07mm (0.0028 in)
Standard bore diameter 87.500 - 87.512 mm (3.4449 - 3.4453 in)
Maximum bore diameter 87.52 mm (3.4457 in)
12 point main bearing cap bolt diameter
Standard 7.500 - 7.600 mm (0.2953 - 0.2992 in)
Minimum 7.20 mm (0.2835 in)
Piston diameter 87.406 - 87.416 mm (3.4412 - 3.4416 in)
Oil clearance
Standard 0.084 - 0.106 mm (0.0033 - 0.0042 in)
Maximum oil clearance 0.13 mm (0.0051 in)
Ring groove clearance
No. 1 0.020 - 0.070 mm (0.0008 - 0.0028 in)
No. 2 0.020 - 0.060 mm (0.0008 - 0.0024 in)
Ring end gap
Standard
No. 1 0.25 - 0.35 mm (0.0098 - 0.0138 in)
No. 2 0.35 - 0.45 mm (0.0138 - 0.0177 in)
Oil (side rail) 0.15 - 0.40 mm (0.0059 - 0.0157 in)
Maximum
No. 1 0.95 mm (0.0374 in)
No. 2 1.05 mm (0.0413 in)
Oil (side rail) 1.00 mm (0.0394 in)
Connecting rod bend 0.05 mm (0.0020 in) max per 100 mm (3.94 in)
Connecting rod twist 0.15 mm (0.0059 in) max per 100 mm (3.94 in)
Connecting rod bushing
inside diameter 22.005 - 22.014 mm (0.8663 - 0.8667 in)
Piston pin diameter 21.997 - 22.006 mm (0.8660 - 0.8664 in)
Oil clearance (Piston pin diameter - bushing inside diameter)
Standard 0.005 - 0.011 mm (0.0002 - 0.0004 in)
Maximum 0.05 mm (0.0020 in)
Connecting rod bolt diameter
Standard 7.2 - 7.3 mm (0.284 - 0.287 in)
Minimum 7.0 mm (0.276 in)
Crankshaft
Circle runout 0.06 mm (0.0024 in) max
Main journal diameter 60.988 - 61.000 mm (2.4011 - 2.4016 in)
Crank pin diameter 52.992 - 53.000 mm (2.0862 - 2.0866 in)
Maximum taper and out-of round 0.02 mm (0.0008 in)