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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Removal and Replacement

REMOVAL

1. REMOVE INTAKE MANIFOLD SUB-ASSEMBLY

a. Remove the intake manifold.

2. REMOVE REAR WATER BY-PASS JOINT.
3. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY.
4. REMOVE STARTER ASSEMBLY




a. Disconnect the starter connector.
b. Remove the nut and disconnect the starter cable.
c. Remove the bolt and disconnect the engine wire protector.
d. Remove the 2 bolts and starter.

INSTALLATION

1. INSTALL STARTER ASSEMBLY




a. Install the wire clamp to the wire protector with the bolt.

Torque: 9.8 N.m (100 kgf.cm, 87 in.lbf)

b. Connect the starter cable with the nut.

Torque: 9.8 N.m (100 kgf.cm, 87 in.lbf)

c. Connect the starter connector.




d. Install the starter with the 2 bolts.

Torque: 39 N.m (398 kgf.cm, 29 ft.lbf)

2. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY.
3. INSTALL REAR WATER BY-PASS JOINT.
4. INSTALL INTAKE MANIFOLD SUB-ASSEMBLY.

a. Install the intake manifold.