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 - Automatic 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. Engine Flywheel Housing Removal
13. Engine Mounting to Stand
14. Cooling 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. Engine Coolant Thermostat Housing Removal
25. Fuel Feed Pipe and Fuel Rail Removal
26. Intake Manifold Tube Removal - Federal Emissions
27. Intake Manifold Tube Removal - California Emissions
28. Intake Manifold Removal - Left
29. Intake Manifold Removal - Right
30. Valve Rocker Arm Cover Removal - Upper Left
31. Valve Rocker Arm Cover Removal - Upper Right
32. Valve Rocker Arm Cover Removal - Lower Left
33. Valve Rocker Arm Cover Removal - Lower Right
34. Fuel Injector Removal
35. Fuel Injector Sleeve Removal
36. Valve Rocker Arm, Shaft, and Push Rod Removal
37. Cylinder Head Removal - Left
38. Cylinder Head Removal - Right
39. Valve Lifter Removal
40. Fuel Injection Pump Removal
41. Water Pump Removal
42. Oil Filter Adapter and Oil Cooler Assembly Removal
43. Crankshaft Front Oil Seal Removal
44. Engine Front Cover Removal
45. Oil Pump Suction Pipe and Screen Assembly Removal
46. Oil Pump Removal
47. Piston Oil Cooling Nozzle Removal
48. Piston, Connecting Rod, and Bearing Removal
49. Camshaft Removal
50. Crankshaft and Bearing Removal
51. Engine Block Clean and Inspect
52. Oil Pan Clean and Inspect - Upper
53. Camshaft and Bearings Clean and Inspect
54. Crankshaft and Bearing Clean and Inspect
55. Crankshaft Balancer Clean and Inspect
56. Engine Flywheel Clean and Inspect
57. Piston and Connecting Rod Disassemble
58. Piston, Connecting Rod, and Bearing Clean and Inspect
59. Piston and Connecting Rod Assemble
60. Cylinder Head Disassemble
61. Cylinder Head Clean and Inspect
62. Valve and Seat Grinding
63. Cylinder Head Assemble
64. Valve Lifter Clean and Inspect
65. Valve Rocker Arm and Shaft Clean and Inspect
66. Piston Oil Cooling Nozzle Clean and Inspect
67. Oil Pump Clean and Inspect
68. Engine Front Cover Clean and Inspect
69. Oil Pan Clean and Inspect - Lower
70. Valve Rocker Arm Cover Clean and Inspect - Lower
71. Valve Rocker Arm Cover Clean and Inspect - Upper
72. Fuel Injector Clean and Inspect
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
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 - Federal Emissions
115. Intake Manifold Tube Installation - California Emissions
116. Fuel Feed Pipe and Fuel Rail Installation
117. Fuel Filter Assembly Installation
118. Engine Coolant Thermostat Housing 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. Cooling Fan Pulley Installation
128. Engine Removal from Stand
129. Engine 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 - Automatic Trans
137. Engine Flywheel Installation - Manual Trans
138. Crankshaft Balancer Installation
139. Starter Installation