All about Chev Duramax V8 Diesel engines
We have available for purchase 2 manuals on the 6.2L & the 6.5L Chev/ Duramax V8 diesel engines that cover information related to the popular engine conversion suited to repower Land cruisers, Nissan patrols,Land rovers,4WD Fords and trucks in the 2 to 5 tonne range.
These engines are used most often here in Australia by farmers and the like to give the run of the mill 4WD`S more grunt for pulling boom sprays and the like.
The Chev Duramax workshop manual covers both the 6.2 & the 6.5L V8 diesel engines...It is a large manual of 310 pages, & gives a complete run down on servicing these engines.
There is a parts catalogue also that covers both engines.
This can be very useful if you are repairing these engines.
.See below some pages from these manuals.
The engine used in the M998 series vehicles is an eight-cylinder, four-cycle, liquid-cooled, naturally aspirated diesel engine. The 6.2L engine has a compression ratio of 21.5:1 and develops approximately 150 horsepower (112 kW) at 3600 rpm. The 6.5L engine has a compression ratio of 21.5:1 and develops approximately 160 horsepower (119 kW) at 3400 rpm. For proper orientation, the left and right sides of the engine are as viewed from the rear.
1990 and above 6.2L and 1994 6.5L engines have the following new and revised parts:
*Cylinder Heads. The 1990 cylinder heads have been revised to meet 1990 emissions standards. Precombustion Valves. The 1990 engine is equipped with reverse throat precombustion chambers.
Exhaust Valves. The 1990 exhaust valves are coated with chrome to prevent burning and to increase durability.
*Exhaust Valve Stem Seal. The 1990 engine is equipped with a new exhaust valve stem seal that is not available for previous model engines.
Cylinder Head Gaskets. The 1990 cylinder head gaskets have new circular combustion seals and are made of a non-asbestos material.
Fuel Injection Pump. The 1994 fuel injection pump has a TP sensor and a revised calibration procedure.
Fuel Injection Pump. The 1990 fuel injection pump has a new governor and a revised calibration procedure.
*Fuel Injection Nozzles. The 1990 fuel injection nozzles are shorter and are orientated ten degrees from the vertical.
*Fuel Injection Lines. The 1990 engine is equipped with high pressure fuel injection lines.
Fuel Injection Line Brackets. The 1990 fuel injection line brackets have been revised to provide clearance for the injection nozzles.
*RPM Sensors. The 1994 engine is equipped with two rpm sensors. One is for STE-ICE-R and one is for the engine.
*Fan Cut-Off Switch. The 1994 engine is equipped with a fan cut-off switch which replaced the kick-down switch.
*These 1990 parts are not interchangeable with parts for previous model engines. Differences in maintenance procedures are identified where applicable. Refer to engine decal number on left rocker arm cover before ordering replacement parts.
d. Studs. Replace all bent and stretched studs. Repair minor thread damage with a thread restorer file.
Replace studs having stripped or damaged threads as outlined below:
(1) Remove, using a stud remover. Back studs out slowly to avoid heat buildup and seizure which
can cause stud to break off.
(2) If studs break off too short to use with a stud remover, use extractor to remove.
(3) Replacement studs have a special coating and must have a small amount of antiseize compound
(Appendix B, Item 3) applied on threads before stud is installed. Install replacement stud slowly to prevent
heat buildup and snapping off.
(1) Remove gears using pullers, as required.
(2) Use the same methods described in paragraph 2-11.b.(2) for castings tO remove minor nicks,
burrs, or scratches on gear teeth.
(3) If keyways are worn or enlarged, replace gear.
f. Bushings and Bushing Type Bearings. When bushings and bushing-type bearings seize to a
shaft and spin in the bore, the associated part must also be inspected and replaced, as required.
g. Oil Seals.
(1) Remove oil seals, being careful not to damage casting or adapter bore.
(2) Always install new seal in bore using proper seal replacing tool.
h. Cylinder Block or Cylinder Head. Repair of cylinder block and cylinder head is limited to procedures outlined in paragraphs 2-16 and 2-21. Cylinder block or cylinder head must be replaced if measurements are outside tolerance limits listed in table 2-2 or table 2-3.
a. Cleanliness is essential in all component assembly operations. Dirt and dust, even in minute
quantities, are abrasive. Parts must be cleaned as specified, and kept clean. Wrap or cover parts and
components when assembly procedures are not immediately completed.
b. Coat all bearings and contact surfaces with engine oil (MIL-L-2104) to ensure lubrication of parts
during initial operation after repair.
c. Use new gaskets and preformed packings during assembly of all components.
9. Install valve (2) in valve guide (4) from which it was removed.
Clearance must be 0.001-0.003 in. (0.026-0.076 mm). Excessive valve stem clearance will cause excessive oil consumption and may cause valve breakage.
• Intake and exhaust valves are available with 0.0035 in.
(0.089 mm) and 0.0137 in. (0.349 mm) oversize stems.
• If valve stem clearance is more than 0.0027 in. (0.068 mm), valve
guide must be reamed to next size and oversized valve installed. If unable to produce clearance with oversize valve, replace cylinder head.
10. Using dial indicator, measure valve stem clearance. Dial indicator must contact valve stem (1) just
above valve guide (4) and at a right angle to the valve stem (1). Drop valve (2) approximately 1/16 in. (1.6 mm) off valve seat (3) and move side-to-side when taking measurement.
11. Repeat steps 9 and 10 for remaining valves (2) and valve guides (4).
12. Inspect cold start advance switch (6) and engine temperature sending unit (5) for damage. Replace
d. Refacing Valves
1. Using valve face grinding machine, grind valve face (7) on all valves (2) to 45".
2. Maintain a minimum of 1/32 in. (0.80 mm) margin (8) on all valves (2). If margin falls below
specifications, replace valve.
e. Grinding Valve Seats
1. Using valve seat grinding kit, grind all valve seats (3) to 46°.
If valve seat width exceeds specifications, valve seat width must be narrowed.
2. Measure width of intake valve seats (3). Valve seats (3) must not be wider than 1/16 in. (1.53 mm).
3. Measure width of exhaust valve seats (3). Valve seats (3) must not be wider than 3/32 in. (2.36 mm).
For general assembly instructions, refer to para. 2-12.
1. Apply OE/HDO to exhaust valve (18) and install valve (18) in valve guide (15) from which it was
•Valve caps on exhaust valves are rotaters.
• Perform step 2 for 6.5L engines and 1990 and above 6.2L engines. Perform step 3 for previous model 6.2L engines.
2. Install seal (21), valve spring shim (14), valve spring (13), valve stem seal (12), shield (11), and valve cap (9) on exhaust valve (18).
3. Install valve spring shim (14), valve spring (13), shield (11), and valve cap (9) on exhaust valve (12).
4. Using spring compressor, compress valve spring (13) and install valve seal (10) in groove (17) in exhaust valve (18) and install valve keys (8). Slowly release spring compressor.
5. Apply OE/HDO to intake valve (19) and install valve (19) in valve guide (16) from which it was removed.
6. Install valve spring shim (2), valve spring (3), shield (4), and valve cap (6) to intake valve (19).
7. Using valve spring compressor, compress valve spring (3) and install valve seal (5) in groove (20) in intake valve (19) and install valve keys (7). Slowly release spring compressor.
8. Check installed height of valve springs (3) measuring from top of valve spring shim (2) to top of shield (4).
9. Spring height must be 1-13/16 in. (46 mm). If spring height is greater, remove valve spring (3) and add spring shim(s) (2) to bring spring height within specifications.
10. Repeat steps 1 through 9 for remaining valves and opposite cylinder head.
Chev Duramax V8 Diesel 6.2-6.5
1# workshop manual au$35.00
2# parts catalog au$35.00
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