Engine Overhaul C/K (GMT 800)

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

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

Engine Overhaul G Van

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

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

Engine Overhaul B 7

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