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

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System Specifications














































Cylinder Head Bolts





Replace the bolts
First pass 20 Nm
Second pass 60 Nm
Final pass Tighten 130°

Cylinder Head Inspection





Front-rear 0.50 mm
Lateral 0.20 mm
Cylinder head height (1999) 129.0 ± 0.05
Cylinder head height, new cylinder head (2000-05) 129.0 ± 0.05
Maximum machining 0.30 mm

Intake Manifold Fasteners 19 Nm

Camshaft Cover Screws





First pass: Install camshaft cover
Second pass: Install press tools 999 5454
Third pass: Tighten camshaft cover screws alternately, keeping it parallel to cylinder head
Final pass: Install all screws and tighten

Variable Valve Timing Center Screw 120 Nm

Exhaust Manifold Studs 20 Nm
Lubricate stud threads with paste P/N 116 1408

Exhaust Manifold Nuts 25 Nm
Install new nuts