Engine Overhaul

EDITED BY
AGUK ZUHDI
 DEFINITION & PROCESS
 DEFINITION: The process of restoring
and maintaining an equipment, machine,
or system in a serviceable condition.
 Overhaul involves :
 (1) Partial or complete disassembly of the
item,
 (2) Inspection to detect damaged, defective,
or worn parts,
 (3) Repair or replacement of such parts, and

 (4) Reassembly, testing, and trial-run prior to

returning the item to its full operating level..
The things that should be
considered involves of
overhaul
1. Make sure the diesel engine in cold
conditions
2. Water cooling jacket should be in an empty
condition by draining.
3. Make sure that all piping system
connections to the cylinder head must be
independent position.
4. The piston position should in the top dead
center (TDC) to uninstall the cylinder head.
Remove Engine

Place engine securely on an engine stand

 Remove Accessories

Remember to take photos- bag and label the parts and fasteners
 Remove Intake and Valve
train Components

Label the pushrods – this is to identify if you find a bent one later
to look at the other parts for that cylinder.
 Remover Cylinder Heads
The Engine’s
Identification
Number is
Found Here

move the head bolts in reverse sequence--- Check for damage especially
ween cylinders
 Remove Lifters

Rotate the engine – it will pop the lifters up for easy of removal
 Ridge Ream Each
Cylinder

ge develops over time and must be removed to allow the piston to be rem
 Remove all Ridges

Two wrenches opposite of each other give you good control

 Remove Oil Pan and
Inspect
ark the main
nd rod caps
r reinstallation

se number and
etter sets

1 3
2
4

This is a four-bolt main – Pay attention to the oil pickup

screen, look for debris
Remove Gaskets and Scrape
Away Crud

Wiggle out the oil dipstick tube, it will be damaged if you don’t.
 Remove Balancer and Front
Cover

Loosen the
Main Bolts
In Reverse
Remove Timin
Sequence
Gears and Cha
Toss Them

emove the Harmonic balancer with the proper tool or you will damage it.
 Remove Pistons and
Main Caps

he pistons out with a plastic hammer– tap the mains from front to back t
 Remove Crank and
Camshaft

Knock out the

Freeze plugs Clean out water Jack
holes
 Remove Camshaft
Bearings

You need a specific tool for this– clean out all bolt holes with a tap
 Clean the Internal Area

pecially the oil galleries

 Clean Out Lifter Area

d tipper with a rag soaked in cleaner works well for areas you can’t get y
 Inspect Cylinder heads

Check everywhere, the heads are very prone to cracks and damage.
Cracks- You Don’t Want To
See This
 Clean the Heads

ower brush works well and inspect head for cracks again, cover and plu
ports and valves if you don’t rebuild the heads. (why wouldn’t you?)
Spring Tool and Valve
Tool

You will need to measure spring

Tension and height
 Cylinder Head
Disassembly

a “C” valve tool to remove valves—Keep everything in order

Inspect Valve, Springs, and
Rotator
 Inspect For Cracks

Check Here
 Valve Grinding

This resurfaces the

valve angle
 Cut & Check Valve Seat

Use Prussian Blue

to check the
contact between
valve and seat
 Valve Angles

Seat
45 degrees

15 degrees

60 degrees
 Clean and Inspect
Pistons

At times you can reuse pistons, replacing them will improve the rebuild
Clean and Inspect the
Entire Engine
Preparation for Painting
 Acquire a Rebuild Kit

This kit is a Mater rebuild kit complete with the crank rods and pistons.
an get a rebuild kits without these items or smaller camshaft and valve train kits
 Paint Heads

Cover valve area and block ports

 Paint Block

nternal parts, you don’t need to paint where the oil will be, use high hea
 Measure, Measure,
Measure

suring throughout the rebuild process will insure you buy the necessary
 Install Camshaft

are with the cam and it’s bearings when installing. Over lube this as you
Install Lifters

Lube the lifters heavily

Measure Ring Gap

This gap needs to be precise, file the gap to

specs
 Install and Bolt Main
Caps
ake sure you
ne up the oils hole
r the bearings

You will want to confirm the inside diameter is correct and round
 Bolt and Torque Crank

Over lube
Everything

Use Assembly
Grease

Install
Freeze Plug

fications and sequence for this and anything else in engine!!!!!!!!!!!!!!!!!

Fit the Ring

Protect the rod

Use wood in the vise

 Lube the Rod Bearings

Oil the rings

Use engine oil

Use assembly grease

Prep Pistons for
Installation

Align the ring gaps---in thirds

 Install Pistons Use a ring
Compressing to

Use a plastic hammer

andle

Install pistons
one at a time
and torque to
specs
 Installing Timing Chain

Mark the aligning

Points with white out
And align them for
proper gear timing
 Clean and Prep the Cylinder
Heads

Some people send

the heads out to
be reworked,
or buy replacement
heads
 Bolt and Torque the
Heads

Use Specs and

Sequence Make sure you kee
the gaskets aligne
 Install Rockers and
Pushrods

Use plenty of lube, this is the last area that gets oil on startup
 Adjust Rockers Arms

e slack out, turn the rod in your fingers and turn adjuster until the rod stops
r do this.
 Prepare the Front Cover

he timing marks again just to make sure. Use a little extra sealer in the
 Install Front Cover

ube seal as you

lace the cover over
he crank

Use specs
 Install Harmonic
Balancer

Use specs
 Prep For Intake Manifold

a good sealer here to help the intake seal. Take care to keep gasket align
 Place the Gaskets

Use a little
extra sealer in
the corners

a good sealer here to help the intake seal. Take care to keep gasket align
 Install intake and
Distributor

can wait for the distributor until later, if so covet the openings in the int
 Install Oil Pump and
Filter

You need
To adjust
The screen.
How?

Install the oil

dipstick
Wires Now or Later
 Wire Looms are
Important

ou may wait until

xhaust is installed
 Install Oil Pan

Install a
fuel
pump also

Use a good
sealant here

Don’t turn engine

Over if carb is
installed
 Install Accessories
Carburetor
Valve covers

Water pump

Exhaust manifolds
 Engine Storage
 Bag and oil the engine if you plan to
store the engine.
 Store engine in a place that is dry.
 You can place it on a wood skid to
recover you stand.
 Engine Break In
 Lots of conflicting info out there.
 Mr. B way.
 Spin the oil pump shaft with drill and get oil
pressure in engine-replace distributor
 Start engine, spot time the distributor and check
for leaks and make adjustments
 If no problems, run engine at idle for two
minutes, the change rpms, two minutes each rpm
range.
 Don’t exceed four thousand rpms for the first five
hundred miles. Change oil at 500 miles. Them at
2000
 Misc.
 Make sure you clean and inspect everything
through the rebuild process, this will prevent you
from rebuilding a cracked block for instance.
 Follow the book, specs, procedures, tests, info,
measurements and sequences are all critical for
success.
 Organization is key.
 Replace all parts if you can.
 Sorry to say, it is cheaper to get a “crate” engine
now days- saves time, money and worry. They
even have a warrantee that you can’t provide.