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