Overhaul Procedure Steps

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