Overhaul Procedure Steps

ENGINE OVERHAUL

RPO K05 - Heater ENG Block
RPO KA3 - Heater Engine Block, 220V

In order to overhaul, follow the sequence below.

1. Draining Fluids and Oil Filter Removal
2. Crankshaft Balancer Removal
3. Engine Flywheel Removal
4. Clutch Pilot Bearing Removal
5. Oil Level Indicator and Tube Removal
6. Oil Filter Adapter Removal
7. Intake Plenum Removal
8. Intake Manifold Removal
9. Intake Manifold Flange Removal
10. Water Crossover Removal
11. Exhaust Manifold Removal - Left
12. Exhaust Manifold Removal - Right
13. Crankcase Vent Housing Removal
14. Drive Belt Tensioner Removal
15. Timing Belt Front Cover Removal
16. Camshaft Cover Removal - Left
17. Camshaft Cover Removal - Right
18. Timing Belt Removal
19. Camshaft Drive Sprocket Removal
20. Timing Belt Tensioner Pulley Removal
21. Water Pump Removal
22. Timing Belt Rear Cover Removal
23. Engine Coolant Thermostat Housing Removal
24. Camshaft Removal - Left
25. Camshaft Removal - Right
26. Valve Lifter Removal
27. Cylinder Head Removal - Left
28. Cylinder Head Removal - Right
29. Engine Oil Cooler Removal
30. Oil Pan Removal
31. Oil Pump Suction Pipe and Screen Assembly Removal
32. Oil Pan Baffle Removal
33. Oil Pump Removal
34. Piston, Connecting Rod, and Bearing Removal
35. Crankshaft Rear Oil Seal Removal
36. Crankshaft and Bearing Removal
37. Engine Block Disassemble - Without K05 and KA3
38. Engine Block Disassemble - With K05
39. Engine Block Disassemble - With KA3
40. Engine Block Clean and Inspect
41. Cylinder Boring and Honing
42. Crankshaft and Bearing Clean and Inspect
43. Engine Flywheel Clean and Inspect
44. Piston and Connecting Rod Disassemble
45. Piston, Connecting Rod, and Bearing Clean and Inspect
46. Piston and Connecting Rod Assemble
47. Camshaft and Bearings Clean and Inspect
48. Camshaft Cover Clean and Inspect
49. Cylinder Head Disassemble
50. Cylinder Head Clean and Inspect
51. Cylinder Head Assemble
52. Oil Pump Disassemble
53. Oil Pump Clean and Inspect
54. Oil Pump Assemble
55. Timing Belt Front Cover Clean and Inspect
56. Oil Pan Clean and Inspect
57. Intake Plenum Manifold Disassemble
58. Intake Plenum Manifold Clean and Inspect
59. Intake Plenum Manifold Assemble
60. Intake Manifold Disassemble
61. Intake Manifold Clean and Inspect
62. Intake Manifold Assemble
63. Exhaust Manifold Clean and Inspect
64. Water Pump Clean and Inspect
65. Engine Oil Cooler Clean and Inspect
66. Engine Block Assemble - Without KA3 and K05
67. Engine Block Assemble - With KA3
68. Engine Block Assemble - With K05
69. Thread Repair
70. Service Prior to Assembly
71. Engine Prelubing
72. Crankshaft and Bearing Installation
73. Crankshaft Rear Oil Seal Installation
74. Piston, Connecting Rod, and Bearing Installation
75. Oil Pump Installation
76. Oil Pan Baffle Installation
77. Oil Pump Suction Pipe and Screen Assembly Installation
78. Oil Pan Installation
79. Engine Oil Cooler Installation
80. Cylinder Head Installation - Left
81. Cylinder Head Installation - Right
82. Valve Lifter Installation
83. Camshaft Installation - Left
84. Camshaft Installation - Right
85. Engine Coolant Thermostat Housing Installation
86. Oil Level Indicator and Tube Installation
87. Timing Belt Rear Cover Installation
88. Water Pump Installation
89. Timing Belt Tensioner Pulley Installation
90. Camshaft Drive Sprocket Installation
91. Timing Belt Installation
92. Timing Belt Timing Adjustment
93. Camshaft Cover Installation - Left
94. Camshaft Cover Installation - Right
95. Timing Belt Front Cover Installation
96. Drive Belt Tensioner Installation
97. Crankcase Vent Housing Installation
98. Exhaust Manifold Installation - Left
99. Exhaust Manifold Installation - Right
100. Water Crossover Installation
101. Intake Manifold Flange Installation
102. Intake Manifold Installation
103. Intake Plenum Installation
104. Oil Filter Adapter Installation
105. Clutch Pilot Bearing Installation
106. Engine Flywheel Installation
107. Crankshaft Balancer Installation