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