Overhaul Procedure Steps

ENGINE OVERHAUL
In order to overhaul, follow the sequence below.

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