Overhaul Procedure Steps

ENGINE OVERHAUL

RPO K19: Reactor System, AIR Injection
RPO 9C2: Governor, Electronic Speed Sensor, 65 MPH

In order to overhaul, follow the sequence below.

1. Draining Fluids and Oil Filter Removal
2. Engine Flywheel Removal - Auto Trans
3. Engine Flywheel Removal - Manual Trans
4. Clutch Pilot Bearing Removal
5. Oil Level Indicator and Tube Removal
6. Exhaust Manifold Removal - Left with RPO K19
7. Exhaust Manifold Removal - Left without RPO K19
8. Exhaust Manifold Removal - Right with RPO K19
9. Exhaust Manifold Removal - Right without RPO K19
10. Water Pump Removal
11. Crankshaft Balancer Removal
12. Valve Rocker Arm Cover Removal - Left
13. Valve Rocker Arm Cover Removal - Right
14. Distributor Removal
15. Throttle Body Removal - Without RPO 9C2
16. Intake Manifold Removal
17. Valve Rocker Arm and Push Rod Removal
18. Cylinder Head Removal - Left
19. Cylinder Head Removal - Right
20. Valve Lifter Removal
21. Oil Pan Removal
22. Oil Pump, Pump Screen and Deflector Removal
23. Engine Front Cover Removal
24. Timing Chain and Sprockets Removal
25. Camshaft Removal
26. Piston, Connecting Rod, and Bearing Removal
27. Crankshaft Rear Oil Seal Removal
28. Crankshaft and Bearings Removal
29. Oil Filter Adapter Removal
30. Engine Block Plug Removal
31. Engine Block Clean and Inspect
32. Cylinder Boring and Honing
33. Crankshaft and Bearings Clean and Inspect
34. Crankshaft Balancer Clean and Inspect
35. Engine Flywheel Clean and Inspect
36. Piston and Connecting Rod Disassemble
37. Piston, Connecting Rod, and Bearings Clean and Inspect
38. Piston Selection
39. Piston and Connecting Rod Assemble
40. Camshaft Bearing Removal
41. Camshaft and Bearings Clean and Inspect
42. Camshaft Bearing Installation
43. Timing Chain and Sprockets Clean and Inspect
44. Valve Rocker Arm and Push Rods Clean and Inspect
45. Valve Lifters and Guides Clean and Inspect
46. Cylinder Head Disassemble
47. Cylinder Head Clean and Inspect
48. Valve Guide Reaming/Valve and Seat Grinding
49. Cylinder Head Assemble
50. Oil Pump Disassemble
51. Oil Pump Clean and Inspect
52. Oil Pump Assemble
53. Valve Rocker Arm Cover Clean and Inspect
54. Oil Pan Clean and Inspect
55. Engine Front Cover Clean and Inspect
56. Intake Manifold Disassemble - Upper
57. Intake Manifold Disassemble - Lower
58. Intake Manifold Clean and Inspect - Upper
59. Intake Manifold Clean and Inspect - Lower
60. Intake Manifold Assemble - Upper
61. Intake Manifold Assemble - Lower
62. Exhaust Manifold Clean and Inspect - Without RPO K19
63. Exhaust Manifold Clean and Inspect - With RPO K19
64. Water Pump Clean and Inspect
66. Thread Repair
66. Service Prior to Assembly
67. Engine Block Plug Installation
68. Oil Filter Adapter Installation
69. Crankshaft and Bearings Installation
70. Crankshaft Rear Oil Seal Installation
71. Piston, Connecting Rod, and Bearing Installation
72. Camshaft Installation
73. Timing Chain and Sprockets Installation
74. Engine Front Cover Installation
75. Oil Pump, Pump Screen and Deflector Installation
76. Oil Pan Installation
77. Valve Lifter Installation
78. Cylinder Head Installation - Left
79. Cylinder Head Installation - Right
80. Valve Rocker Arm and Push Rod Installation
81. Intake Manifold Installation
82. Throttle Body Installation - Without RPO 9C2
83. Distributor Installation
84. Valve Rocker Arm Cover Installation - Left
85. Valve Rocker Arm Cover Installation - Right
86. Crankshaft Balancer Installation
87. Water Pump Installation
88. Exhaust Manifold Installation - Left with RPO K19
89. Exhaust Manifold Installation - Left without RPO K19
90. Exhaust Manifold Installation - Right with RPO K19
91. Exhaust Manifold Installation - Right without RPO K19
92. Oil Level Indicator and Tube Installation
93. Clutch Pilot Bearing Installation
94. Engine Flywheel Installation - Auto Trans
95. Engine Flywheel Installation - Manual Trans
96. Engine Set-Up and Testing