Overhaul Procedure Steps

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

1. Engine Oil Cooler Removal
2. Draining Fluids and Oil Filter Removal
3. Crankshaft Balancer Removal
4. Engine Flywheel Removal
5. Engine Mounting to Stand
6. Oil Level Indicator and Tube Removal
7. Starter Removal
8. Intake Manifold Removal
9. Fuel Rail and Injectors Removal
10. Turbocharger Removal
11. Exhaust Manifold Removal
12. Camshaft Cover Removal
13. Engine Front Cover and Oil Pump Removal
14. Timing Chain and Tensioner Removal
15. Intake Camshaft, Follower, and Adjuster Removal
16. Exhaust Camshaft, Follower, and Adjuster Removal
17. Balance Shaft Drive Chain and Tensioner Removal
18. Balance Shaft Removal
19. Water Pump Removal
20. Cylinder Head Removal
21. Oil Pan Removal
22. Piston, Connecting Rod, and Bearing Removal
23. Lower Crankcase Removal
24. Crankshaft and Bearing Removal
25. Engine Block Disassemble
26. Engine Block Cleaning and Inspection
27. Cylinder Honing
28. Cylinder Sleeve Removal
29. Cylinder Sleeve Installation
30. Crankshaft Balancer Cleaning and Inspection
31. Engine Flywheel Cleaning and Inspection
32. Crankshaft and Bearing Cleaning and Inspection
33. Piston and Connecting Rod Disassemble
34. Piston, Connecting Rod, and Bearing Cleaning and Inspection
35. Piston and Connecting Rod Assemble
36. Camshaft Cleaning and Inspection
37. Timing Chain and Sprocket Cleaning and Inspection
38. Balance Shaft Cleaning and Inspection
39. Balance Shaft Drive Chain and Sprockets Cleaning and Inspection
40. Cylinder Head Disassemble
41. Cylinder Head Cleaning and Inspection
42. Valve and Seat Grinding
43. Cylinder Head Assemble
44. Oil Pump Disassemble
45. Oil Pump Assemble
46. Turbocharger Cleaning and Inspection
47. Fuel Rail and Injectors Cleaning and Inspection
48. Intake Manifold Cleaning and Inspection
49. Exhaust Manifold Cleaning and Inspection
50. Oil Pan Cleaning and Inspection
51. Thread Repair
52. Service Prior to Assembly
53. Engine Block Assemble
54. Crankshaft and Bearing Installation
55. Lower Crankcase Installation
56. Crankshaft Rear Oil Seal Installation
57. Piston, Connecting Rod, and Bearing Installation
58. Cylinder Head Installation
59. Intake Camshaft, Follower, and Adjuster Install
60. Exhaust Camshaft, Follower, and Adjuster Install
61. Balance Shaft Installation
62. Water Pump Installation
63. Balance Shaft to Engine Timing
64. Balance Shaft Drive Chain and Tensioner Install
65. Timing Chain, Sprocket, and Tensioner Installation
66. Crankshaft Front Oil Seal Installation
67. Engine Front Cover and Oil Pump Installation
68. Engine Oil Cooler Installation
69. Engine Flywheel Installation
70. Oil Pan Installation
71. Crankshaft Balancer Installation
72. Camshaft Cover Installation
73. Oil Filter and Adapter Installation
74. Fuel Rail and Injectors Installation
75. Intake Manifold Installation
76. Exhaust Manifold Installation
77. Turbocharger Installation
78. Starter Installation
79. Oil Level Indicator and Tube Installation
80. Engine Prelubing