Overhaul Procedure Steps

ENGINE OVERHAUL

RPO KA3 - Heater Engine Block, 220V
RPO K05 - Heater ENG Block

In order to overhaul, follow the sequence below.

1. Timing Belt Timing Adjustment
2. Draining Fluids and Oil Filter Removal
3. Crankshaft Balancer Removal
4. Engine Flywheel Removal
5. Clutch Pilot Bearing Removal
6. Oil Level Indicator and Tube Removal
7. Oil Filter Adapter Removal
8. Intake Plenum Removal
9. Intake Manifold Removal
10. Intake Manifold Flange Removal
11. Water Crossover Removal
12. Exhaust Manifold Removal - Left
13. Exhaust Manifold Removal - Right
14. Crankcase Vent Housing Removal
15. Drive Belt Tensioner Removal
16. Timing Belt Front Cover Removal
17. Camshaft Cover Removal - Left
18. Camshaft Cover Removal - Right
19. Timing Belt Removal
20. Camshaft Drive Sprocket Removal
21. Timing Belt Tensioner Pulley Removal
22. Water Pump Removal
23. Timing Belt Rear Cover Removal
24. Engine Coolant Thermostat Housing Removal
25. Camshaft Removal - Left
26. Camshaft Removal - Right
27. Valve Lifter Removal
28. Cylinder Head Removal - Left
29. Cylinder Head Removal - Right
30. Engine Oil Cooler Removal
31. Oil Pan Removal
32. Oil Pump Suction Pipe and Screen Assembly Removal
33. Oil Pan Baffle Removal
34. Oil Pump Removal
35. Piston, Connecting Rod, and Bearing Removal
36. Crankshaft Rear Oil Seal Removal
37. Crankshaft and Bearing Removal
38. Engine Block Disassemble - Without K05 and KA3
39. Engine Block Disassemble - With K05
40. Engine Block Disassemble - With KA3
41. Engine Block Clean and Inspect
42. Cylinder Boring and Honing
43. Crankshaft and Bearing Clean and Inspect
44. Engine Flywheel Clean and Inspect
45. Piston and Connecting Rod Disassemble
46. Piston, Connecting Rod, and Bearing Clean and Inspect
47. Piston and Connecting Rod Assemble
48. Camshaft and Bearings Clean and Inspect
49. Camshaft Cover Clean and Inspect
50. Cylinder Head Disassemble
51. Cylinder Head Clean and Inspect
52. Cylinder Head Assemble
53. Oil Pump Disassemble
54. Oil Pump Clean and Inspect
55. Oil Pump Assemble
56. Timing Belt Front Cover Clean and Inspect
57. Oil Pan Clean and Inspect
58. Intake Plenum Manifold Disassemble
59. Intake Plenum Manifold Clean and Inspect
60. Intake Plenum Manifold Assemble
61. Intake Manifold Disassemble
62. Intake Manifold Clean and Inspect
63. Intake Manifold Assemble
64. Exhaust Manifold Clean and Inspect
65. Water Pump Clean and Inspect
66. Engine Oil Cooler Clean and Inspect
67. Engine Block Assemble - Without KA3 and K05
68. Engine Block Assemble - With KA3
69. Engine Block Assemble - With K05
70. Thread Repair
71. Service Prior to Assembly
72. Engine Prelubing
73. Crankshaft and Bearing Installation
74. Crankshaft Rear Oil Seal Installation
75. Piston, Connecting Rod, and Bearing Installation
76. Oil Pump Installation
77. Oil Pan Baffle Installation
78. Oil Pump Suction Pipe and Screen Assembly Installation
79. Oil Pan Installation
80. Engine Oil Cooler Installation
81. Cylinder Head Installation - Left
82. Cylinder Head Installation - Right
83. Valve Lifter Installation
84. Camshaft Installation - Left
85. Camshaft Installation - Right
86. Engine Coolant Thermostat Housing Installation
87. Oil Level Indicator and Tube Installation
88. Timing Belt Rear Cover Installation
89. Water Pump Installation
90. Timing Belt Tensioner Pulley Installation
91. Camshaft Drive Sprocket Installation
92. Timing Belt Installation
93. Camshaft Cover Installation - Left
94. Camshaft Cover Installation - Right
95. Timing Belt Front Cover Installation
96. Drive Belt Tensioner Installation
97. Crankcase Vent Housing Installation
98. Exhaust Manifold Installation - Left
99. Exhaust Manifold Installation - Right
100. Water Crossover Installation
101. Intake Manifold Flange Installation
102. Intake Manifold Installation
103. Intake Plenum Installation
104. Oil Filter Adapter Installation
105. Clutch Pilot Bearing Installation
106. Engine Flywheel Installation
107. Crankshaft Balancer Installation