Detroit Diesel Engine Series 92 Service Manual
Detroit Diesel Engine Series 92 Service Manual
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Detroit Diesel Engine Series 92 Service Manual
This manual provides instruction for servicing on-highway, industrial, generator set, and marine
applications of the Detroit Diesel Series 92 Engines.
Specifically a basic overview of each major component and system along with recommendations
for removal, cleaning, inspection, criteria for replacement, repair and installation and mechanical
troubleshooting are contained in this manual.
DDEC® III/IV troubleshooting concerns are contained in the DDEC III/IV Single ECM
Troubleshooting Guide, 6SE497.
TABLE OF CONTENTS
GENERAL INFORMATION ...................................................................... 1
SCOPE AND USE OF THIS MANUAL ..................................................... 3
SAFETY PRECAUTIONS ........................................................................ 3
FLUOROELASTOMER (VITON) CAUTION ............................................. 10
SERVICE PARTS AVAILABILITY ............................................................. 11
CLEARANCE AND TORQUE SPECIFICATIONS .................................... 11
THE TWO CYCLE PRINCIPLE FOR DIESEL ENGINES ........................ 12
GENERAL DESCRIPTION ..................................................................... 13
DDEC DIAGNOSTIC READER CAUTION ............................................... 15
DDEC I ..................................................................................................... 16
DDEC II .................................................................................................... 17
DDEC III .................................................................................................. 17
GENERAL SPECIFICATIONS ................................................................ 18
ENGINE MODEL, SERIAL NUMBER AND OPTION LABEL ................... 21
REPAIR AND REPLACE .......................................................................... 24
DISASSEMBLY ....................................................................................... 25
CLEANING ............................................................................................... 25
INSPECTION .......................................................................................... 26
ASSEMBLY .............................................................................................. 27
FABRICATING, ALTERING, REMOVING AND DISPOSING OF
GASKETS ................................................................................................ 27
ENGLISH TO METRIC CONVERSION .................................................... 28
DECIMAL AND METRIC EQUIVALENTS ................................................ 30
SPECIFICATIONS ................................................................................... 30
1 ENGINE
1.1 CYLINDER BLOCK ................................................................................. 1-3
1.2 CYLINDER BLOCK END PLATES ........................................................... 1-38
1.3 CYLINDER HEAD ................................................................................... 1-47
1.4 VALVE AND INJECTOR OPERATING MECHANISM .............................. 1-74
1.5 EXHAUST VALVES ................................................................................. 1-102
1.6 VALVE ROCKER COVERS ...................................................................... 1-126
1.7 CRANKSHAFT ........................................................................................ 1-132
1.8 CRANKSHAFT OIL SEALS (FRONT AND REAR) .................................. 1-166
1.9 CRANKSHAFT CAP ................................................................................ 1-176
1.10 CRANKSHAFT MAIN BEARING SHELLS ............................................... 1-180
1.11 ENGINE FRONT COVER ........................................................................ 1-197
1.12 CRANKSHAFT OUTBOARD BEARING SUPPORT (TRUNNION) .......... 1-202
1.13 CRANKSHAFT REAR OUTBOARD BEARING SUPPORT ..................... 1-210
1.14 CRANKSHAFT VIBRATION DAMPER ..................................................... 1-223
1.15 CRANKSHAFT PULLEY .......................................................................... 1-238
1.16 FLYWHEEL ............................................................................................. 1-243
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