Overhaul Procedure Steps

ENGINE OVERHAUL

RPO K19: Reactor System, AIR Injection
RPO 9C2: Governor, Electronic Speed Sensor, 65 MPH

In order to overhaul, follow the sequence below.

1. Draining Fluids and Oil Filter Removal
2. Engine Flywheel Removal
3. Oil Level Indicator and Tube Removal
4. Exhaust Manifold Removal - Left with RPO K19
5. Exhaust Manifold Removal - Left without RPO K19
6. Exhaust Manifold Removal - Right with RPO K19
7. Exhaust Manifold Removal - Right without RPO K19
8. Water Pump Removal
9. Crankshaft Balancer Removal
10. Valve Rocker Arm Cover Removal - Left
11. Valve Rocker Arm Cover Removal - Right
12. Distributor Removal
13. Throttle Body Removal - With RPO 9C2
14. Throttle Body Removal - Without RPO 9C2
15. Intake Manifold Removal
16. Valve Rocker Arm and Push Rod Removal
17. Cylinder Head Removal - Left
18. Cylinder Head Removal - Right
19. Valve Lifter Removal
20. Oil Pan Removal
21. Oil Pump, Pump Screen and Deflector Removal
22. Engine Front Cover Removal
23. Timing Chain and Sprockets Removal
24. Camshaft Removal
25. Piston, Connecting Rod, and Bearing Removal
26. Crankshaft Rear Oil Seal Removal
27. Crankshaft and Bearings Removal
28. Oil Filter Adapter Removal
29. Engine Block Plug Removal
30. Engine Block Clean and Inspect
31. Cylinder Boring and Honing
32. Crankshaft and Bearings Clean and Inspect
33. Crankshaft Balancer Clean and Inspect
34. Engine Flywheel Clean and Inspect
35. Piston and Connecting Rod Disassemble
36. Piston, Connecting Rod, and Bearings Clean and Inspect
37. Piston Selection
38. Piston and Connecting Rod Assemble
39. Camshaft Bearing Removal
40. Camshaft and Bearings Clean and Inspect
41. Camshaft Bearing Installation
42. Timing Chain and Sprockets Clean and Inspect
43. Valve Rocker Arm and Push Rods Clean and Inspect
44. Valve Lifters and Guides Clean and Inspect
45. Cylinder Head Disassemble
46. Cylinder Head Clean and Inspect
47. Valve Guide Reaming & Valve and Seat Grinding
48. Cylinder Head Assemble
49. Oil Pump Disassemble
50. Oil Pump Clean and Inspect
51. Oil Pump Assemble
52. Valve Rocker Arm Cover Clean and Inspect
53. Oil Pan Clean and Inspect
54. Intake Manifold Disassemble - Upper with RPO 9C2
55. Intake Manifold Disassemble - Upper without RPO 9C2
56. Intake Manifold Disassemble - Lower
57. Intake Manifold Clean and Inspect - Upper
58. Intake Manifold Clean and Inspect - Lower
59. Intake Manifold Assemble - Lower
60. Intake Manifold Assemble - Upper with RPO 9C2
61. Intake Manifold Assemble - Upper without RPO 9C2
62. Exhaust Manifold Clean and Inspect - With RPO K19
63. Exhaust Manifold Clean and Inspect - Without RPO K19
64. Water Pump Clean and Inspect
65. Thread Repair
66. Service Prior to Assembly
67. Engine Block Plug Installation
68. Oil Filter Adapter Installation
69. Crankshaft and Bearings Installation
70. Crankshaft Rear Oil Seal Installation
71. Piston, Connecting Rod, and Bearing Installation
72. Camshaft Installation
73. Timing Chain and Sprockets Installation
74. Engine Front Cover Installation
75. Oil Pump, Pump Screen and Deflector Installation
76. Oil Pan Installation
77. Valve Lifter Installation
78. Cylinder Head Installation - Left
79. Cylinder Head Installation - Right
80. Valve Rocker Arm and Push Rod Installation
81. Intake Manifold Installation
82. Throttle Body Installation - With RPO 9C2
83. Throttle Body Installation - Without RPO 9C2
84. Distributor Installation
85. Valve Rocker Arm Cover Installation - Left
86. Valve Rocker Arm Cover Installation - Right
87. Crankshaft Balancer Installation
88. Water Pump Installation
89. Exhaust Manifold Installation - Left with RPO K19
90. Exhaust Manifold Installation - Left without RPO K19
91. Exhaust Manifold Installation - Right with RPO K19
92. Exhaust Manifold Installation - Right without RPO K19
93. Oil Level Indicator and Tube Installation
94. Engine Flywheel Installation
95. Engine Set-Up and Testing