Lots of bits and pieces in here that are really good advice. I just went through a lot of this myself assembling from scratch, and will give a few bits of my findings:
There is no comprehensive list anywhere I have found, and many steps can be done interchangeably without too many problems. Also, you absolutely will do things over (and maybe over again) despite the best planning: out of order on a small thing, wrong hardware, forgot a part, something doesn't work, etc.
A few areas are critical to do in order. Ones that come to mind are:
- running all the hard lines (hydraulics, fuel, etc) before something big like an engine is in the way, but after the subframes/suspension/brakes are in. If you are making these lines, everything you need to connect to must already be in (brakes, master cylinder, etc.), which could change the order for you, and you may want to remove the brake booster after again, before installing the engine.
- Easier to install the A/C condensor before the motor, but definitely before the radiator
- Running the wiring after insulation, but before most anything else on the interior. I did mine after the pedal box, but probably would have been easier without that in the way
- Hook up as much of the fuse block wires as possible (and check them) before sliding it into position. If you want the bulk of wires to go through the mounting bracket, you can actually slide the full wired block through at just the right angle. changing wires once they are through that bracket is difficult
- Deal with sunroof drains while the interior is empty as possible, before headliner
- Get carpet, upper pillars and headliner in pretty early after wiring. Once the headliner is in, get the interior aluminum trim in place to hold the edge well
- Order of the front interior is absolutely critical (carpet, pillar trim, HVAC, dash parts, console. Many of these will only be accessible sequentially. To me, this was the single most important order, and one where we do need a comprehensive step by step. I almost posted one a few weeks ago, probably worth doing one in the DIY section
- Make sure everything electrical is working both a piece at a time and in total before you install the upper dash, lower dash, center console sides or lower interior trim. Otherwise you may need to dig/pull apart to solve.
- Leave all exterior trim, grills, lights, rubber till very late just in case you need to fix any paint after all that assmbly
- Front/rear windows, hood and doors come near the end. As mentioned, trunk is sort of independent (inside and lid), do it whenever you want
