Diesel Engine Repair Manual: GM & Ford

The Haynes Tech Book Diesel Repair Manual covers a variety of General Motors and Ford lightweight trucks, vans and passenger cars. The Haynes manual is designed for DIY mechanics or beginners and features a progressive format that starts with basic repairs and works its way up to more complex tasks. The manual is written with simple step-by-step instructions to walk the home mechanic through the repair process to ensure perfect results. The fully illustrated guide includes everything from simple repairs through complex maintenance procedures to keep your Ford or General Motors vehicle running its best. The included pictures, illustrations and diagrams are intended to enhance the instructions and help beginner mechanics or those less familiar with diesel engines locate and replace components as needed. This manual covers the following General Motors and Ford vehicles: GM 350 cu. in. 5.7 liter, 379 cu. in. 6.2 liter, and 397 cu. in. 6.5 liter; Ford 420 cu. in. 6.9 liter, 445 cu. in. 7.3 liter and 445 cu. in. 7.3 liter Power Stroke.
Book Excerpt: Diesel Engine Repair Manual GM, Ford V8 Engines HIGH PRESSURE SYSTEM: GENERAL INFORMATION

The heart of GM's 5.7L, 6.2L, and 6.5 diesel engines is the high-pressure system which delivers fuel to the combustion chambers. The high-pressure system consists of the injection pump, the injection nozzles and the metal lines between the pump and the nozzles. The high-pressure system sounds pretty simple in principle, but in fact it's anything but simple. The high-pressure system performs many functions, many more than a carburetor or fuel injection system on a gasoline-powered vehicle. Not only must it meter - in accordance with the load and speed of the engine - the quantity of fuel required for each cycle of the engine. It must also develop the high pressure necessary to inject fuel into each cylinder at a precisely determined instant in its operation cycle (firing order). And it must control the rate at which the fuel is injected, atomize and distribute the fuel throughout the combustion chamber, and start and end each injection cycle abruptly. Obviously, the high-pressure system is fairly complex.

FLUID LEVEL CHECKS NOTE: The following are fluid level checks to be done on a 250 mile or weekly basis. Additional fluid level checks can be found in specific maintenance procedures which follow. Regardless of intervals, be alert to fluid leaks under the vehicle which would indicate a fault to be corrected immediately.

Fluids are an essential part of the lubrication and cooling systems. Because the fluids gradually become depleted and/or contaminated during normal operation of the vehicle, they must be periodically replenished. See Recommended lubricants and fluids at the beginning of this Chapter before adding fluid to any of the following components. Note: The vehicle must be on level ground when fluid levels are checked.

The purpose of this manual is to help you service and overhaul the Ford 6.9L and 7.3L light truck diesels and General Motors automobile and light pickup truck 5.7L, 6.2L and 6.5L diesel engines. Step-by-step instructions. Fully-illustrated for the home mechanic. From simple maintenance to major repairs, including engine overhaul. This manual also covers: Tools and equipment. Shop practices. Troubleshooting. Routine maintenance. Engine repairs and overhaul. Cooling, fuel and electrical systems. Subject: Diesel engine repair. General Motors, Ford. ISBN-10: 156392188X | ISBN-13: 9781563921889 | Haynes 10330