Overhaul Procedure Steps

ENGINE OVERHAUL

RPO L56 - Engine Diesel 8 Cyl 6.5L Turbo VIN S
RPO L57 - Engine Diesel 8 Cyl 6.5L HO
RPO L65 - Engine Diesel 8 Cyl 6.5L Turbo HO VIN F

In order to overhaul, follow the sequence below.

1. Accessory Removal
2. Engine Flywheel Removal
3. Clutch Pilot Bearing Removal
4. Oil Fill Tube Removal
5. Oil Level Indicator and Tube Removal
6. Engine Coolant Thermostat Removal
7. Intake Manifold Removal - RPO L57, L65
8. Intake Manifold Removal - RPO L65
9. Intake Manifold Removal - Upper RPO L56
10. Engine Wiring Harness Assembly Removal
11. Turbocharger Removal
12. Oil Pump Drive Removal
13. Exhaust Manifold Removal - RPO L65
14. Water Pump Removal
15. Fuel Injection Pump Removal
16. Crankshaft Balancer Removal
17. Engine Front Cover Removal
18. Timing Chain Wear Check
19. Timing Chain and Camshaft Sprocket Removal
20. Valve Rocker Arm Cover Removal
21. Valve Rocker Arm, Shaft, and Push Rod Removal
22. Cylinder Head Removal
23. Valve Lifter Removal
24. Camshaft Removal
25. Oil Pan Removal
26. Oil Pump Removal
27. Piston, Connecting Rod, and Bearing Removal
28. Crankshaft Rear Oil Seal Removal
29. Crankshaft and Bearings Removal
30. Camshaft Bearing Removal
31. Oil Filter Adapter Removal
32. Engine Block Plug Removal
33. Piston Oil Cooling Nozzle 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 Selection
42. Piston and Connecting Rod Assemble
43. Camshaft and Bearings Clean and Inspect
44. Timing Chain and Sprockets Clean and Inspect
45. Valve Rocker Arm and Shaft Disassemble
46. Valve Rocker Arm and Shaft Clean and Inspect
47. Valve Rocker Arm and Shaft Assemble
48. Valve Lifters and Guides Clean and Inspect
49. Cylinder Head Disassemble
50. Cylinder Head Clean and Inspect
51. Valve Guide Reaming/Valve and Seat Grinding
52. Cylinder Head Assemble
53. Oil Pump Disassemble
54. Oil Pump Clean and Inspect
55. Oil Pump Assemble
56. Engine Front Cover Clean and Inspect
57. Valve Rocker Arm Cover Clean and Inspect
58. Oil Pan Clean and Inspect
59. Intake Manifold Clean and Inspect
60. Exhaust Manifold Clean and Inspect
61. Water Pump Clean and Inspect
62. Fuel Injection Pump Clean and Inspect
63. Service Prior to Assembly
64. Piston Oil Cooling Nozzle Installation
65. Engine Block Plug Installation
66. Oil Filter Adapter Installation
67. Camshaft Bearing Installation
68. Crankshaft and Bearings Installation - RPO L65
69. Crankshaft Rear Oil Seal Installation
70. Piston, Connecting Rod, and Bearing Installation
71. Oil Pump Installation
72. Oil Pan Installation
73. Camshaft Installation
74. Valve Lifter Installation
75. Cylinder Head Installation
76. Valve Rocker Arm, Shaft, and Push Rod Installation
77. Valve Rocker Arm Cover Installation
78. Timing Chain and Sprockets Installation
79. Engine Front Cover Installation
80. Crankshaft Balancer Installation
81. Fuel Injection Pump Installation
82. Water Pump Installation
83. Exhaust Manifold Installation - RPO L65
84. Oil Pump Drive Installation
85. Turbocharger Installation
86. Engine Wiring Harness Assembly Installation
87. Intake Manifold Installation - RPO L57, L65
88. Intake Manifold Installation - RPO L56
89. Intake Manifold Installation - Upper RPO L65
90. Engine Coolant Thermostat Installation
91. Oil Level Indicator and Tube Installation
92. Oil Fill Tube Installation
93. Clutch Pilot Bearing Installation
94. Engine Flywheel Installation
95. Accessory Installation
96. Engine Set-Up and Testing
97. Thread Repair