1. The document provides step-by-step instructions for removing a diesel engine from a vehicle and overhauling it. It lists 14 steps for removing the engine, which include draining fluids, disconnecting wiring and linkages, and using an engine lift to remove the engine. 2. The overhaul process involves removing engine components like the intake, valve train, cylinder heads, pistons, and crankshaft for inspection and cleaning. Components are measured and checked for wear before being reassembled. 3. Reassembly instructions provide details on lubricating parts, torquing bolts, installing gaskets and seals, and adjusting components like the valve rockers. Accessories are reinstalled last.

4. REMOVING DIESEL ENGINE FROM THE VEHICLE:
1.PARK THE VEHICLE ON A LEVEL SURFACE.
2.CHOKE ALL FOUR WHEELER WITH WOODEN BLOCK.
3.UNSCREW THE BONNET MOUNTINGS AND REMOVE IT ALONG WITH THE GRILL.
4.DISCONNECT THE BATTERY CONNECTION AND TAKE OUT THE BATTERY.
5.DRAIN THE RADIARTOR.
6. DRAIN THE ENGINE OIL.
REMOVE THE AIR CLEANER.
7. REMOVE THE RADIATOR HOSES
8.DISCONNECT THE WIRE CONNECTION OF THE STARING MOTOR AND ALTERNATOR
,HEATERPLUG CONNECTION.
9.DISCONNECT THE FUEL SUPPLY PIPES FROM FUEL TANK TO FUEL PUMPS.
10.DISCONNECT THE ACCELERATOR CONNECTION.

5. 11.REMOVE THE CLUTCH AND GEAR LINKAGES.
12.DISCONNECT THE PROPELLER SHAFT AND GEARBOX END.
13.FIT A SUITABLE ENGINE LIFTING BRACKET.
14.REMOVE THE ENGINE MOUNTING BRACKET.

6. Engine Overhaul
CHEVY 350

7. Remove Engine
Place engine securely on an engine stand

8. Remove Accessories
Remember to take photos- bag and label the parts and fasteners

9. 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.

10. Remover Cylinder Heads
Remove the head bolts in reverse sequence--- Check for damage especially
between cylinders
The Engine’s
Identification
Number is
Found Here

11. Remove Lifters
Rotate the engine – it will pop the lifters up for easy of removal

12. Remove Oil Pan and Inspect
This is a four-bolt main – Pay attention to the oil pickup screen, look for
debris
1
2
3
4
Mark the main
and rod caps
for reinstallation
Use number and
Letter sets

13. Remove Gaskets and Scrape Away Crud
Wiggle out the oil dipstick tube, it will be damaged if you don’t.

14. Remove Balancer and Front Cover
Loosen the
Main Bolts
In Reverse
Sequence
Remove the Harmonic balancer with the proper tool or you will damage it.
Remove Timing
Gears and Chain
Toss Them

15. Remove Pistons and Main Caps
Tap the pistons out with a plastic hammer– tap the mains from front to back to loosen

16. Remove Crank and Camshaft
Knock out the
Freeze plugs Clean out water Jacket
holes

17. Remove Camshaft Bearings
You need a specific tool for this– clean out all bolt holes with a tap

18. Clean the Internal Area
Especially the oil galleries

19. Inspect Cylinder heads
Check everywhere, the heads are very prone to cracks and damage.

20. Cracks- You Don’t Want To See This

21. Clean the Heads
A power brush works well and inspect head for cracks again, cover and plug
the ports and valves if you don’t rebuild the heads. (why wouldn’t you?)

22. Inspect Valve, Springs, and Rotator

23. Inspect For Cracks
Check Here

24. Valve Grinding
This resurfaces the
valve angle

25. Cut & Check Valve Seat
Use Prussian Blue
to check the
contact between
valve and seat

26. Valve Angles
Seat
45 degrees
15 degrees
60 degrees

27. Clean and Inspect Pistons
At times you can reuse pistons, replacing them will improve the rebuild

28. Clean and Inspect the Entire Engine

29. Measure, Measure, Measure
Measuring throughout the rebuild process will insure you buy the necessary items

30. ASSEMBLING OF ENGINE PARTS

31. Install and Bolt Main Caps
You will want to confirm the inside diameter is correct and round
Make sure you
line up the oils hole
for the bearings

32. Bolt and Torque Crank
Use specifications and sequence for this and anything else in engine!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!
Over lube
Everything
Use Assembly
Grease
Install
Freeze Plugs

33. Fit the Ring
Protect the rod
Use wood in the vise

34. Lube the Rod Bearings
Use assembly grease
Oil the rings
Use engine oil

35. Prep Pistons for Installation
Align the ring gaps---in thirds

36. Installing Timing Chain
Mark the aligning
Points with white out
And align them for
proper gear timing

37. Clean and Prep the Cylinder Heads
Some people send
the heads out to
be reworked,
or buy replacement
heads

38. Install Rockers and Pushrods
Use plenty of lube, this is the last area that gets oil on startup

39. Adjust Rockers Arms
Adjust the slack out, turn the rod in your fingers and turn adjuster until the rod stops spinning
Don’t over do this.

40. Prepare the Front Cover
Check the timing marks again just to make sure. Use a little extra sealer in the corners.

41. Install Front Cover
Lube seal as you
place the cover over
the crank
Use specs

42. Install Harmonic Balancer
Use specs

43. Prep For Intake Manifold
Use a good sealer here to help the intake seal. Take care to keep gasket aligned

44. Place the Gaskets
Use a good sealer here to help the intake seal. Take care to keep gasket aligned
Use a little
extra sealer in
the corners

45. INSTALL INTAKE AND INJECTOR
You can wait for the distributor until later, if so covet the openings in the intake!!!!

46. Install Oil Pump and Filter
Install the oil
dipstick
You need
To adjust
The screen.
How?

47. Install Oil Pan
Use a good
sealant here
Don’t turn engine
Over if carb is
installed
Install a fuel
pump also

48. Install Accessories
Valve covers
Exhaust manifolds
Water pump