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Diesel Engine Repair Manual: General Motors & Ford Light Trucks, Vans, Passenger Cars

Item #HY10330
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  • Item Description
  • Table of Contents
  • Specifications

This manual covers General Motors and Ford: light trucks, vans, passenger cars. 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


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.


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


  • Introduction
  • How Diesel Engines are Different
  • Buying Parts
  • A Place to Work
  • Tools and Equipment
  • Diesel Engine Troubleshooting
  • GM 5.7L, 6.2L and 6.5L V8 Engines
  • Ford 6.9L and 7.3L Engines
  • Engine Overhaul Procedures
  • Compression Check
  • Engine Removal
  • Engine Rebuilding Alternatives
  • Engine Overhaul - Disassembly Sequence
  • Engine Block - Cleaning
  • Engine Block - Inspection
  • Engine Overhaul - Reassembly
  • Initial Start-up and Break-in After Overhaul

  • Publisher: Haynes Manuals
  • Pages: 284 - Hundreds of b&w photos and illustrations
  • Binding: Paperback - 8.25 x 10.75 inches
  • ISBN: 978-1-56392-188-9
  • Diesel Engine Repair Manual: GM & Ford
    3.5 Stars based on 2 Review(s)
    Wahoo, ne
    2 Stars

    Didn't cover what I needed.
    October 23, 2014
    I needed to know how to do the fuel heater gaskets and it didn't even show a picture of my fuel system for a 1989 ford 250 7.3 diesel it had most of the others but not mine so I am not so happy. Haven't checked if it covers other parts of my truck. Very disappointed.
    Does cover most diesels, even Chevy.
    Covers other years of fuel heaters that sit on top of filter but not the 89s. I have a Ford and expected it to be better, what a dissapointment.

    5 Stars
    I would recommend this item to a friend.

    fast shipping
    May 2, 2014
    Easy purchase process, fast shipping! Bought for my step son, he loves it!