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