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GM 6.2 & 6.5 Liter Diesel Engines: How to Rebuild

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Finally, a rebuild and performance guide for GM 6.2 and 6.5L diesel engines!

In the late 1970s and early 1980s, there was considerable pressure on the Detroit automakers to increase the fuel efficiency for their automotive and light-truck lines. While efficient electronic engine controls and computer-controlled gas engine technology was still in the developmental stages, the efficiency of diesel engines was already well documented during this time period. As a result, General Motors added diesel engine options to its car and truck lines in an attempt to combat high gas prices and increase fuel efficiency.

The first mass-produced V-8 diesel engines of the era, the 5.7L variants, appeared in several General Motors passenger-car models beginning in 1978 and are often referred to as the Oldsmobile Diesels because of the number of Oldsmobile cars equipped with this option. This edition faded from popularity in the early 1980s as a result of falling gas prices and quality issues with diesel fuel suppliers, giving the cars a bad reputation for dependability and reliability. The 6.2L appeared in 1982 and the 6.5L in 1992, as the focus for diesel applications shifted from cars to light trucks. These engines served faithfully and remained in production until 2001, when the new Duramax design replaced it in all but a few military applications.

While very durable and reliable, most of these engines have a lot of miles on them, and many are in need of a rebuild. This book will take you through the entire rebuild process step by step from diagnosis to tear down, inspection to parts sourcing, machining, and finally reassembly. Also included is valuable troubleshooting information, detailed explanations of how systems work, and even a complete Stanadyne DB2 rebuild section to get the most out of your engine in the modern era.

If you have a 6.2, or 6.5L GM diesel engine, this book is a must-have item for your shop or library.

ISBN-13: 9781613255605

Media Type: Paperback

Publisher: CarTech

Publication Date: 08-25-2020

Pages: 160

Product Dimensions: 8.40(w) x 10.90(h) x 0.40(d)

Dr. John F. Kershaw has more than 50 years of experience in automotive technology. He is the author of 15 General Motors technical training publications as well as the published author of 6 automotive textbooks. He has been a Volkswagen enthusiast for many years. In addition, he worked for several Volkswagen dealerships as a technician and has considerable hands-on experience building Super Vee engines.

Table of Contents

Preface

Acknowledgments

About the Author

Chapter 1: Introduction to Diesel Engines

Diesel Internal Combustion Engine Terms

Combustion Chambers

Engine Operation

Valve Timing

Combustion Process

Power and Speed Control

Fuel Injection Timing

Chapter 2: Tools, History, and Engine Systems

Special Service Tools

Engine History

Construction

The Fuel System

Evaluating and Diagnosing the Fuel System

Engine Noise Diagnosis

Glow Plug Systems

Injection Pump Timing

Compression Testing

Checking Turbo Boost Pressure

Cooling System Issues

Chapter 3: Engine Removal

Chapter 4: Engine Disassembly

Chapter 5: Stanadyne DB2 Pump Service

Pump Operation

Injection Pump Disassembly and Assembly

Transfer Pump Service

Optional Inspections and Adjustments

Injection Pump Rotor

Pump Reassembly

Injection Pump Test Stand

Chapter 6: Engine Inspection, Cleaning, and Machining

Engine Block Inspection and Service

Chapter 7: Assembly and Installation

Bottom-End Build

Installation

Chapter 8: Diagnostics and Modifications

Mechanical System Diagnosis

Automatic Transmission TPC/VRV DB2 Systems

6.5L DS4 EFI Diagnosis

DS4 Pump Fuel Flow

6.5L EFI Diagnostics

6.5L Diagnostic Issues

Early 5.7L Olds Diesel Engines

Performance Upgrades

Appendix

Source Guide