Overhaul Procedure Steps

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

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