Detroit Diesel Engine Series 92 Service Manual

 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