Overhaul Procedure Steps

ENGINE OVERHAUL

RPO NC8 - California System Emissions, ULEV

In order to overhaul, follow the sequence below.

1. Draining Fluids and Oil Filter Removal
2. Crankshaft Balancer Removal
3. Engine Flywheel Removal
4. Drive Belt Tensioner Removal - Right
5. Oil Level Indicator and Tube Removal
6. Water Outlet Removal
7. Water Pump Removal
8. Intake Manifold Removal - Upper
9. Intake Manifold Removal - Lower
10. Exhaust Manifold Removal - Left
11. Exhaust Manifold Removal - Right without RPO NC8
12. Exhaust Manifold Removal - Right with RPO NC8
13. Valve Rocker Arm Cover Removal - Left
14. Valve Rocker Arm Cover Removal - Right
15. Valve Rocker Arm and Push Rod Removal
16. Cylinder Head Removal - Left
17. Cylinder Head Removal - Right
18. Valve Lifter Removal
19. Crankshaft Front Oil Seal Removal
20. Engine Front Cover Removal
21. Oil Filter Adapter Removal
22. Timing Chain and Sprocket Removal
23. Balance Shaft Removal
24. Camshaft Removal
25. Crankshaft Rear Oil Seal Removal
26. Crankshaft Rear Oil Seal and Housing Removal
27. Oil Pan Removal
28. Oil Pump Suction Pipe and Screen Assembly Removal
29. Piston, Connecting Rod, and Bearing Removal
30. Crankshaft and Bearing Removal
31. Engine Block Plug Removal
32. Camshaft Bearing Removal
33. Balancer Shaft Bearing Removal
34. Engine Block Clean and Inspect
35. Cylinder Boring and Honing
36. Crankshaft and Bearing Clean and Inspect
37. Crankshaft Balancer Clean and Inspect
38. Engine Flywheel Clean and Inspect
39. Piston and Connecting Rod Disassemble
40. Piston, Connecting Rod, and Bearing Clean and Inspect
41. Piston and Connecting Rod Assemble
42. Camshaft and Bearings Clean and Inspect
43. Timing Chain and Sprocket Clean and Inspect
44. Valve Rocker Arm and Push Rod Clean and Inspect
45. Valve Lifter and Guide Clean and Inspect
46. Cylinder Head Disassemble
47. Cylinder Head Clean and Inspect
48. Valve Guide Reaming, and Valve and Seat Grinding
49. Cylinder Head Assemble
50. Oil Pump Disassemble
51. Oil Pump Clean and Inspect
52. Engine Front Cover Clean and Inspect
53. Oil Pump Assemble
54. Valve Rocker Arm Cover Clean and Inspect
55. Oil Pan Clean and Inspect
56. Intake Manifold Clean and Inspect - Upper
57. Intake Manifold Clean and Inspect - Lower
58. Exhaust Manifold Clean and Inspect
59. Water Pump Clean and Inspect
60. Balance Shaft Clean and Inspect
61. Thread Repair
62. Service Prior to Assembly
63. Balancer Shaft Bearing Installation
64. Camshaft Bearing Installation
65. Engine Block Plug Installation
66. Crankshaft and Bearing Installation
67. Piston, Connecting Rod, and Bearing Installation
68. Oil Pump Suction Pipe and Screen Assembly Installation
69. Oil Pan Installation
70. Crankshaft Rear Oil Seal and Housing Installation
71. Crankshaft Rear Oil Seal Installation
72. Camshaft Installation
73. Balance Shaft Installation
74. Timing Chain and Sprocket Installation
75. Oil Filter Adapter Installation
76. Engine Front Cover Installation
77. Crankshaft Front Oil Seal Installation
78. Valve Lifter Installation
79. Cylinder Head Installation - Right
80. Cylinder Head Installation - Left
81. Valve Rocker Arm and Push Rod Installation
82. Valve Rocker Arm Cover Installation - Right
83. Valve Rocker Arm Cover Installation - Left
84. Exhaust Manifold Installation - Right without RPO NC8
85. Exhaust Manifold Installation - Right with RPO NC8
86. Exhaust Manifold Installation - Left
87. Intake Manifold Installation - Lower
88. Intake Manifold Installation - Upper
89. Water Pump Installation
90. Water Outlet Installation
91. Oil Level Indicator and Tube Installation
92. Drive Belt Tensioner Installation - Right
93. Engine Flywheel Installation
94. Crankshaft Balancer Installation
95. Engine Prelubing