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, Screen and Crankshaft Oil 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 Bearing 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 Bearing 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 Bearing 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 Sprocket Clean and Inspect
43. Valve Rocker Arm and Push Rod 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, and Valve and Seat Grinding
48. Cylinder Head Assemble
49. Oil Pump Disassemble
50. Oil Pump Clean and Inspect
51. Oil Pump Assemble
52. Oil Pan Clean and Inspect
53. Engine Front Cover Clean and Inspect
54. Valve Rocker Arm Cover Clean and Inspect
55. Intake Manifold Disassemble - Upper with RPO 9C2
56. Intake Manifold Disassemble - Upper without RPO 9C2
57. Intake Manifold Disassemble - Lower
58. Intake Manifold Clean and Inspect - Upper
59. Intake Manifold Clean and Inspect - Lower
60. Intake Manifold Assemble - Upper with RPO 9C2
61. Intake Manifold Assemble - Upper without RPO 9C2
62. Intake Manifold Assemble - Lower
63. Exhaust Manifold Clean and Inspect - With RPO K19
64. Exhaust Manifold Clean and Inspect - Without RPO K19
65. Water Pump Clean and Inspect
66. Thread Repair
67. Service Prior to Assembly
68. Engine Block Plug Installation
69. Oil Filter Adapter Installation
70. Crankshaft and Bearing Installation
71. Crankshaft Rear Oil Seal Installation
72. Piston, Connecting Rod, and Bearing Installation
73. Camshaft Installation
74. Timing Chain and Sprockets Installation
75. Engine Front Cover Installation
76. Oil Pump, Screen and Crankshaft Oil Deflector Installation
77. Oil Pan Installation
78. Valve Lifter Installation
79. Cylinder Head Installation - Right
80. Cylinder Head Installation - Left
81. Valve Rocker Arm and Push Rod Installation
82. Intake Manifold Installation
83. Throttle Body Installation - With RPO 9C2
84. Throttle Body Installation - Without RPO 9C2
85. Distributor Installation
86. Valve Rocker Arm Cover Installation - Right
87. Valve Rocker Arm Cover Installation - Left
88. Crankshaft Balancer Installation
89. Water Pump Installation
90. Exhaust Manifold Installation - Right with RPO K19
91. Exhaust Manifold Installation - Right without RPO K19
92. Exhaust Manifold Installation - Left with RPO K19
93. Exhaust Manifold Installation - Left without RPO K19
94. Oil Level Indicator and Tube Installation
95. Engine Flywheel Installation
96. Engine Set-Up and Testing