1 Preparation • Drain all fluids (coolant, oil, etc.) and disconnect the battery. • Remove all external components such as the turbocharger, exhaust manifold, air intake, and accessories. 2 Cylinder Head and Components • Remove the cylinder head bolts and carefully lift the head off the engine. • Remove the rocker arms, injectors, and any other components attached to the cylinder head assembly. 3 Piston and Liners • Remove the pistons and liners. If the liners are damaged or worn, you’ll need to replace them or machine the counterbores if required. This ensures a proper fit and correct deck height. • Inspect the pistons for signs of wear or damage, such as scoring or cracks. 4 Counterbore Machining (if needed) • If the counterbores are damaged or out of specification, you’ll need to machine them and use shims to adjust the height, so the liner sits properly. 5 Reassembly • Install new pistons, liners, and rings. Ensure the piston rings are properly installed to avoid any blow-by. • Install new bearings (main and rod bearings) along with the new cylinder head and injectors. 6 Final Checks and Fluids • Refill the engine with fresh oil, coolant, and any other necessary fluids. • Once everything is reassembled, check for leaks, and ensure the torque specs are met on all bolts. 7 Engine Testing • Start the engine, and monitor for any unusual noises, leaks, or irregularities. • Adjust any necessary components, such as the valve lash and injector settings.
