Overhaul Procedure Steps

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