Engine Overhaul for GMC Truck GMC P42 Commercial Chassis 1999

Engine Overhaul L57

To disassemble, overhaul, repair or assemble the 6.5L Diesel engine, use the Disassembly, Overhaul, Repair and Assembly sequence listed below.

1. Accessory Removal
2. Engine Flywheel Removal
3. Clutch Pilot Bearing Removal
4. Oil Fill Tube Removal
5. Oil Level Indicator and Tube Removal
6. Thermostat Removal
7. Intake Manifold Removal (L57, L65)
8. Engine Wiring Harness Assembly Removal
9. Turbocharger Removal
10. Oil Pump Drive Removal
11. Exhaust Manifold Removal (L57)
12. Water Pump Removal
13. Fuel Injection Pump Removal
14. Crankshaft Balancer Removal
15. Engine Front Cover Removal
16. Timing Chain Wear Check
17. Timing Chain and Camshaft Sprocket Removal
18. Valve Rocker Arm Cover Removal
19. Valve Rocker Arm, Shaft, and Push Rod Removal
20. Cylinder Head Removal
21. Valve Lifter Removal
22. Camshaft Removal
23. Oil Pan Removal
24. Oil Pump Removal
25. Piston, Connecting Rod, and Bearing Removal
26. Crankshaft Rear Oil Seal Removal
27. Crankshaft and Bearings Removal
28. Camshaft Bearing Removal
29. Oil Filter Adapter Removal
30. Engine Block Plug Removal
31. Piston Oil Cooling Nozzle Removal
32. Engine Block Cleaning and Inspection
33. Cylinder Boring and Honing
34. Crankshaft and Bearing Cleaning and Inspection
35. Crankshaft Balancer Clean and Inspect
36. Engine Flywheel Clean and Inspect
37. Piston and Connecting Rod Disassemble
38. Piston, Connecting Rod, and Bearing Cleaning and Inspection
39. Piston Selection
40. Piston and Connecting Rod Assemble
41. Camshaft and Bearings Cleaning and Inspection
42. Timing Chain and Sprockets Clean and Inspect
43. Valve Rocker Arm and Shaft Disassemble
44. Valve Rocker Arm and Shaft Clean and Inspect
45. Valve Rocker Arm and Shaft Assemble
46. Valve Lifters and Guides Clean and Inspect
47. Cylinder Head Disassemble
48. Cylinder Head Cleaning and Inspection
49. Valve Guide Reaming/Valve and Seat Grinding
50. Cylinder Head Assemble
51. Oil Pump Disassemble
52. Oil Pump Clean and Inspect
53. Oil Pump Assemble
54. Engine Front Cover Clean and Inspect
55. Valve Rocker Arm Cover Clean and Inspect
56. Oil Pan Clean and Inspect
57. Intake Manifold Clean and Inspect
58. Exhaust Manifold Clean and Inspect
59. Water Pump Clean and Inspect
60. Fuel Injection Pump Clean and Inspect
61. Service Prior to Assembly
62. Piston Oil Cooling Nozzle Installation
63. Engine Block Plug Installation
64. Oil Filter Adapter Installation
65. Camshaft Bearing Installation
66. Crankshaft and Bearings Installation (L57)
67. Crankshaft Rear Oil Seal Installation
68. Piston, Connecting Rod, and Bearing Installation
69. Oil Pump Installation
70. Oil Pan Installation
71. Camshaft Installation
72. Valve Lifter Installation
73. Cylinder Head Installation
74. Valve Rocker Arm, Shaft, and Push Rod Installation
75. Valve Rocker Arm Cover Installation
76. Timing Chain and Sprockets Installation
77. Engine Front Cover Installation
78. Crankshaft Balancer Installation
79. Fuel Injection Pump Installation
80. Water Pump Installation
81. Exhaust Manifold Installation (L57)
82. Oil Pump Drive Installation
83. Turbocharger Installation
84. Engine Wiring Harness Assembly Installation
85. Intake Manifold Installation (L57, L65)
86. Thermostat Installation (L57, L65)
87. Oil Level Indicator and Tube Installation
88. Oil Fill Tube Installation
89. Clutch Pilot Bearing Installation
90. Engine Flywheel Installation
91. Accessory Installation
92. Engine Set-Up and Testing
93. Thread Repair

Engine Overhaul L65

To disassemble, overhaul, repair or assemble the 6.5L Diesel engine, use the Disassembly, Overhaul, Repair and Assembly sequence listed below.

1. Accessory Removal
2. Engine Flywheel Removal
3. Clutch Pilot Bearing Removal
4. Oil Fill Tube Removal
5. Oil Level Indicator and Tube Removal
6. Thermostat Removal
7. Intake Manifold Removal (L65)
8. Engine Wiring Harness Assembly Removal
9. Turbocharger Removal
10. Oil Pump Drive Removal
11. Exhaust Manifold Removal (L65)
12. Water Pump Removal
13. Fuel Injection Pump Removal
14. Crankshaft Balancer Removal
15. Engine Front Cover Removal
16. Timing Chain Wear Check
17. Timing Chain and Camshaft Sprocket Removal
18. Valve Rocker Arm Cover Removal
19. Valve Rocker Arm, Shaft, and Push Rod Removal
20. Cylinder Head Removal
21. Valve Lifter Removal
22. Camshaft Removal
23. Oil Pan Removal
24. Oil Pump Removal
25. Piston, Connecting Rod, and Bearing Removal
26. Crankshaft Rear Oil Seal Removal
27. Crankshaft and Bearings Removal
28. Camshaft Bearing Removal
29. Oil Filter Adapter Removal
30. Engine Block Plug Removal
31. Piston Oil Cooling Nozzle Removal
32. Engine Block Cleaning and Inspection
33. Cylinder Boring and Honing
34. Crankshaft and Bearing Cleaning and Inspection
35. Crankshaft Balancer Clean and Inspect
36. Engine Flywheel Clean and Inspect
37. Piston and Connecting Rod Disassemble
38. Piston, Connecting Rod, and Bearing Cleaning and Inspection
39. Piston Selection
40. Piston and Connecting Rod Assemble
41. Camshaft and Bearings Cleaning and Inspection
42. Timing Chain and Sprockets Clean and Inspect
43. Valve Rocker Arm and Shaft Disassemble
44. Valve Rocker Arm and Shaft Clean and Inspect
45. Valve Rocker Arm and Shaft Assemble
46. Valve Lifters and Guides Clean and Inspect
47. Cylinder Head Disassemble
48. Cylinder Head Cleaning and Inspection
49. Valve Guide Reaming/Valve and Seat Grinding
50. Cylinder Head Assemble
51. Oil Pump Disassemble
52. Oil Pump Clean and Inspect
53. Oil Pump Assemble
54. Engine Front Cover Clean and Inspect
55. Valve Rocker Arm Cover Clean and Inspect
56. Oil Pan Clean and Inspect
57. Intake Manifold Clean and Inspect
58. Exhaust Manifold Clean and Inspect
59. Water Pump Clean and Inspect
60. Fuel Injection Pump Clean and Inspect
61. Service Prior to Assembly
62. Piston Oil Cooling Nozzle Installation
63. Engine Block Plug Installation
64. Oil Filter Adapter Installation
65. Camshaft Bearing Installation
66. Crankshaft and Bearings Installation (L65)
67. Crankshaft Rear Oil Seal Installation
68. Piston, Connecting Rod, and Bearing Installation
69. Oil Pump Installation
70. Oil Pan Installation
71. Camshaft Installation
72. Valve Lifter Installation
73. Cylinder Head Installation
74. Valve Rocker Arm, Shaft, and Push Rod Installation
75. Valve Rocker Arm Cover Installation
76. Timing Chain and Sprockets Installation
77. Engine Front Cover Installation
78. Crankshaft Balancer Installation
79. Fuel Injection Pump Installation
80. Water Pump Installation
81. Exhaust Manifold Installation (L65)
82. Oil Pump Drive Installation
83. Turbocharger Installation
84. Engine Wiring Harness Assembly Installation
85. Intake Manifold Installation (Upper-L65)
86. Thermostat Installation (L57, L65)
87. Oil Level Indicator and Tube Installation
88. Oil Fill Tube Installation
89. Clutch Pilot Bearing Installation
90. Engine Flywheel Installation
91. Accessory Installation
92. Engine Set-Up and Testing
93. Thread Repair