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