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

2.0L (LTG) or 2.5L (LCV)

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