Overhaul Procedure Steps

ENGINE OVERHAUL

Note: Camshaft bearings are not servicable. If the camshaft bearings are damaged the engine must be replaced.

In order to overhaul, follow the sequence below.

1. Draining Fluids and Oil Filter Removal
2. Starter Removal
3. Crankshaft Balancer Removal
4. Engine Flywheel Removal - Auto Trans
5. Engine Flywheel Removal - Manual Trans
6. Crankshaft Rear Oil Seal Removal
7. Exhaust Outlet Removal
8. Exhaust Pipe Removal - Left
9. Exhaust Pipe Removal - Right
10. Oil Pan Removal - Lower
11. Oil Pan Removal - Upper
12. Engine Flywheel Housing Removal
13. Engine Mounting to Stand
14. Fan Pulley Removal
15. Power Steering Pump Mounting Bracket Removal
16. Positive Crankcase Ventilation Oil Separator and Hose Removal
17. Generator and Drive Belt Tensioner Bracket Removal
18. Fuel Filter Assembly Removal
19. Fuel Injection Control Module Harness Assembly Removal
20. Fuel Injector Control Module Removal
21. Exhaust Manifold Removal - Left
22. Exhaust Manifold Removal - Right
23. Glow Plug Controller and Glow Plugs Removal
24. Turbocharger Removal
25. Oil Filler Tube Removal
26. Engine Coolant Thermostat Housing Removal
27. Fuel Feed Pipe and Fuel Rail Removal
28. Intake Manifold Tube Removal
29. Intake Manifold Removal - Left
30. Intake Manifold Removal - Right
31. Valve Rocker Arm Cover Removal - Upper Left
32. Valve Rocker Arm Cover Removal - Upper Right
33. Valve Rocker Arm Cover Removal - Lower Left
34. Valve Rocker Arm Cover Removal - Lower Right
35. Fuel Injector Removal
36. Fuel Injector Sleeve Removal
37. Valve Rocker Arm, Shaft, and Push Rod Removal
38. Cylinder Head Removal - Left
39. Cylinder Head Removal - Right
40. Valve Lifter Removal
41. Fuel Injection Pump Removal
42. Water Pump Removal
43. Oil Filter Adapter and Oil Cooler Assembly Removal
44. Crankshaft Front Oil Seal Removal
45. Engine Front Cover Removal
46. Oil Pump Suction Pipe and Screen Assembly Removal
47. Oil Pump Removal
48. Piston Oil Cooling Nozzle Removal
49. Piston, Connecting Rod, and Bearing Removal
50. Camshaft Removal
51. Crankshaft and Bearing Removal
52. Engine Block Clean and Inspect
53. Oil Pan Clean and Inspect - Upper
54. Camshaft and Bearings Clean and Inspect
55. Crankshaft and Bearing Clean and Inspect
56. Crankshaft Balancer Clean and Inspect
57. Engine Flywheel Clean and Inspect
58. Piston and Connecting Rod Disassemble
59. Piston, Connecting Rod, and Bearing Clean and Inspect
60. Piston and Connecting Rod Assemble
61. Cylinder Head Disassemble
62. Cylinder Head Clean and Inspect
63. Valve and Seat Grinding
64. Cylinder Head Assemble
65. Valve Lifter Clean and Inspect
66. Valve Rocker Arm and Shaft Clean and Inspect
67. Piston Oil Cooling Nozzle Clean and Inspect
68. Oil Pump Clean and Inspect
69. Engine Front Cover Clean and Inspect
70. Oil Pan Clean and Inspect - Lower
71. Valve Rocker Arm Cover Clean and Inspect - Lower
72. Valve Rocker Arm Cover Clean and Inspect - Upper
73. Intake Manifold Clean and Inspect
74. Oil Filter Adapter and Oil Cooler Assembly Clean and Inspect
75. Engine Coolant Thermostat Housing Clean and Inspect
76. Exhaust Manifold Clean and Inspect
77. Exhaust Pipe Clean and Inspect
78. Exhaust Outlet Clean and Inspect
79. Fuel Injection Pump Clean and Inspect
80. Turbocharger Clean and Inspect
81. Flywheel Housing Clean and Inspect
82. Water Pump Clean and Inspect
83. Thread Repair
84. Fuel Line Torquing
85. Service Prior to Assembly
86. Engine Prelubing
87. Crankshaft and Bearing Installation
88. Camshaft Installation
89. Piston, Connecting Rod, and Bearing Installation
90. Piston Oil Cooling Nozzle Installation
91. Oil Pump Installation
92. Oil Pump Suction Pipe and Screen Assembly Installation
93. Engine Front Cover Installation
94. Crankshaft Front Oil Seal Installation
95. Oil Filter Adapter and Oil Cooler Assembly Installation
96. Water Pump Installation
97. Fuel Injection Pump Installation
98. Valve Lifter Installation
99. Cylinder Head Gasket Selection
100. Cylinder Head Installation - Left
101. Cylinder Head Installation - Right
102. Valve Rocker Arm, Shaft, and Push Rod Installation
103. Valve Clearance Adjustment
104. Fuel Injector Sleeve Installation
105. Fuel Injector Installation
106. Valve Rocker Arm Cover Installation - Lower Left
107. Valve Rocker Arm Cover Installation - Lower Right
108. Valve Rocker Arm Cover Installation - Upper Left
109. Valve Rocker Arm Cover Installation - Upper Right
110. Intake Manifold Installation - Left
111. Intake Manifold Installation - Right
112. Intake Manifold Tube Installation
113. Fuel Feed Pipe and Fuel Rail Installation
114. Fuel Filter Assembly Installation
115. Engine Coolant Thermostat Housing Installation
116. Oil Filler Tube Installation
117. Turbocharger Installation
118. Glow Plug Controller and Glow Plugs Installation
119. Exhaust Manifold Installation - Left
120. Exhaust Manifold Installation - Right
121. Fuel Injector Control Module Installation
122. Fuel Injection Control Module Harness Assembly Installation
123. Generator and Drive Belt Tensioner Bracket Installation
124. Positive Crankcase Ventilation Oil Separator and Hose Installation
125. Power Steering Pump Mounting Bracket Installation
126. Fan Pulley Installation
127. Engine Removal from Stand
128. Engine Flywheel Housing Installation
129. Oil Pan Installation - Upper
130. Oil Pan Installation - Lower
131. Exhaust Pipe Installation - Left
132. Exhaust Pipe Installation - Right
133. Exhaust Outlet Installation
134. Crankshaft Rear Oil Seal Installation
135. Engine Flywheel Installation - Auto Trans
136. Engine Flywheel Installation - Manual Trans
137. Crankshaft Balancer Installation
138. Starter Installation