Overhaul Procedure Steps

ENGINE OVERHAUL

NOTE: This article lists the sequential steps necessary to overhaul the engine.

^ For the specific step listed below, refer to that step under "Repair Instructions". Repair Instructions

6.6L LGH or LML

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