Overhaul Procedure Steps

ENGINE OVERHAUL

NOTE: This article lists the sequential steps necessary to overhaul the engine.

^ For the specific step listed below, refer to that step under "Repair Instructions". Repair Instructions

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