Overhaul Procedure Steps

ENGINE OVERHAUL

RPO NC1 - Emission System, California
RPO NF7 - Emission System, Federal

In order to overhaul, follow the sequence below.

1. Drive Belt Removal
2. Power Steering Pump Removal
3. Generator Removal
4. Air Conditioning Compressor Removal
5. Drive Belt Idler Pulley Removal
6. Drive Belt Tensioner Removal
7. Crankshaft Balancer Removal
8. Engine Flywheel Removal
9. Crankshaft Rear Oil Seal Removal
10. Oil Level Indicator and Tube Removal
11. Exhaust Manifold Removal - Left without RPO NC1 or NF7
12. Exhaust Manifold Removal - Left with RPO NC1 or NF7
13. Exhaust Manifold Removal - Right without RPO NC1 or NF7
14. Exhaust Manifold Removal - Right with RPO NC1 or NF7
15. Oil Filter Adapter Removal - Without Oil Cooler
16. Oil Filter Adapter Removal - With Oil Cooler
17. Intake Manifold Removal
18. Water Crossover Removal
19. Starter Removal
20. Ignition Coil Module Removal - Left
21. Ignition Coil Module Removal - Right
22. Camshaft Cover Removal - Left
23. Camshaft Cover Removal - Right
24. Engine Front Cover Removal
25. Crankshaft Front Oil Seal Removal
26. Oil Pump Removal
27. Secondary Camshaft Intermediate Drive Chain Removal - Right
28. Secondary Camshaft Intermediate Drive Chain Removal - Left
29. Primary Camshaft Intermediate Drive Chain Removal
30. Camshaft Intermediate Drive Shaft Removal
31. Camshaft Removal - Left Exhaust
32. Camshaft Removal - Left Intake
33. Camshaft Removal - Right Exhaust
34. Camshaft Removal - Right Intake
35. Valve Rocker Arm Removal - Left
36. Valve Rocker Arm Removal - Right
37. Valve Lifter Removal - Left
38. Valve Lifter Removal - Right
39. Cylinder Head Removal - Left
40. Cylinder Head Removal - Right
41. Oil Pan Removal
42. Oil Pump Suction Pipe and Screen Assembly Removal
43. Lower Crankcase Removal
44. Piston, Connecting Rod, and Bearing Removal
45. Crankshaft and Bearing Removal
46. Engine Block Disassemble - Upper
47. Engine Block Clean and Inspect - Upper
48. Engine Block Clean and Inspect - Lower
49. Crankshaft and Bearing Clean and Inspect
50. Crankshaft Balancer Clean and Inspect
51. Engine Flywheel Clean and Inspect
52. Piston and Connecting Rod Disassemble
53. Piston, Connecting Rod, and Bearing Clean and Inspect
54. Piston and Connecting Rod Assemble
55. Camshaft Intermediate Drive Shaft Clean and Inspect
56. Cylinder Head Disassemble
57. Cylinder Head Clean and Inspect
58. Valve Spring Inspection and Measurement
59. Valve and Seat Grinding
60. Cylinder Head Assemble
61. Camshaft Clean and Inspect
62. Valve Lifter Clean and Inspect
63. Valve Rocker Arm Clean and Inspect
64. Camshaft Timing Drive Components Clean and Inspect
65. Oil Pump Disassemble
66. Oil Pump Clean and Inspect
67. Oil Pump Assemble
68. Oil Filter Adapter Disassemble - Without Oil Cooler
69. Oil Filter Adapter Disassemble - With Oil Cooler
70. Oil Filter Adapter Clean and Inspect - Without Oil Cooler
71. Oil Filter Adapter Clean and Inspect - With Oil Cooler
72. Oil Filter Adapter Assemble - Without Oil Cooler
73. Oil Filter Adapter Assemble - With Oil Cooler
74. Oil Pan Clean and Inspect
75. Camshaft Cover Disassemble
76. Camshaft Cover Clean and Inspect
77. Camshaft Cover Assemble
78. Intake Manifold Disassemble
79. Intake Manifold Clean and Inspect
80. Intake Manifold Assemble
81. Exhaust Manifold Clean and Inspect - Left
82. Exhaust Manifold Clean and Inspect - Right
83. Water Pump Clean and Inspect
84. Water Crossover Disassemble
85. Water Crossover Clean and Inspect
86. Water Crossover Assemble
87. Thread Repair
88. Service Prior to Assembly
89. Engine Prelubing
90. Engine Block Assemble - Upper
91. Crankshaft and Bearing Installation
92. Piston, Connecting Rod, and Bearing Installation
93. Lower Crankcase Installation
94. Oil Pump Suction Pipe and Screen Assembly Installation
95. Oil Pan Installation
96. Cylinder Head Installation - Left
97. Cylinder Head Installation - Right
98. Valve Lifter Installation - Left
99. Valve Lifter Installation - Right
100. Valve Rocker Arm Installation - Left
101. Valve Rocker Arm Installation - Right
102. Camshaft Installation - Left Exhaust
103. Camshaft Installation - Left Intake
104. Camshaft Installation - Right Exhaust
105. Camshaft Installation - Right Intake
106. Camshaft Intermediate Drive Shaft Installation
107. Primary Camshaft Intermediate Drive Chain Installation
108. Secondary Camshaft Intermediate Drive Chain Installation - Left
109. Secondary Camshaft Intermediate Drive Chain Installation - Right
110. Oil Pump Installation
111. Crankshaft Front Oil Seal Installation
112. Engine Front Cover Installation
113. Camshaft Cover Installation - Left
114. Camshaft Cover Installation - Right
115. Ignition Coil Module Installation - Left
116. Ignition Coil Module Installation - Right
117. Starter Installation
118. Water Crossover Installation
119. Intake Manifold Installation
120. Oil Filter Adapter Installation - Without Oil Cooler
121. Oil Filter Adapter Installation - With Oil Cooler
122. Exhaust Manifold Installation - Left without RPO NC1 or NF7
123. Exhaust Manifold Installation - Left with RPO NC1 or NF7
124. Exhaust Manifold Installation - Right without RPO NC1 or NF7
125. Exhaust Manifold Installation - Right with RPO NC1 or NF7
126. Oil Level Indicator and Tube Installation
127. Crankshaft Rear Oil Seal Installation
128. Engine Flywheel Installation
129. Crankshaft Balancer Installation
130. Drive Belt Tensioner Installation
131. Drive Belt Idler Pulley Installation
132. Air Conditioning Compressor Installation
133. Generator Installation
134. Power Steering Pump Installation
135. Drive Belt Installation