SERIES 92 SERVICE MANUAL

Diesel engine exhaust and some of its constituents are

known to the State of California to cause cancer, birth
defects, and other reproductive harm.
Always start and operate an engine in a well ventilated
area.
If operating an engine in an enclosed area, vent the
exhaust to the outside.
Do not modify or tamper with the exhaust system or
emission control system.

ABSTRACT

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.
3M Super Tack™ is a trademark of Minnesota Mining and Manufacturing Company. Aeroshell® is a registered trademark of Shell Oil Company.
Allison® is a registered trademark of General Motors Corporation. Alvania® is a registered trademark of Shell Oil Company. Barber-Colman®
is a registered trademark of Barber-Colman Company. Biobor® is a registered trademark of United States Borax and Chemical Corporation.
Cindol® is a registered trademark of E.F. Houghton & Co. DDEC® is a registered trademark of Detroit Diesel Corporation. Delco Remy® is
a registered trademark of Delco Remy America, Inc. Donaldson® is a registered trademark of Donaldson Company, Inc. Dow Corning® is a
registered trademark of Dow Corning Corporation. Endurion® is a registered trademark of Jason Incorporated. Fuel Pro® is a registered trademark
of Davco Manufacturing, L.L.C. Jabsco® is a registered trademark of ITT Industries. Jake Brake® is a registered trademark of Diesel Engine
Retarders, Inc. Kent-Moore® is a registered trademark of SPX Corporation. Leece-Neville® is a registered trademark of Leece-Neville Company.
Loctite® is a registered trademark of Loctite Corporation. Lubriplate® is a registered trademark of Fiske Brothers Refining Company. Lubrite®
is a registered trademark of Henkel Corporation. Mobilgrease® is a registered trademark of Mobil Oil Corporation. Permatex® is a registered
trademark of Loctite Corporation. Power Cool® is a registered trademark of Detroit Diesel Corporation. Power Trac® is a registered trademark of
Detroit Diesel Corporation. Red-Jaket® is a registered trademark of INCOM International, Inc. reliabilt® is a registered trademark of Detroit
Diesel Corporation. Rockford® is a registered trademark of Rockford Powertrain, Inc. Sea Pro® is a registered trademark of Davco Manufacturing,
L.L.C. Shell® is a registered trademark of Shell Oil Corporation. Starrett® is a registered trademark of L.S. Starrett Company. STP® is a
registered trademark of First Brand Corporation. Teflon® is a registered trademark of E.I. DuPont de Nemours and Company, Inc. Texaco® is a
registered trademark of Texaco, Inc. Twin Disc® is a registered trademark of Twin Disc, Inc. Viton® is a registered trademark of Dupont Dow
Elastomers L.L.C. Volvo® is a registered trademark of Volvo Trademark Holding AB. WD-40® is a registered trademark of WD-40 Company.
Woodward® is a registered trademark of Woodward Governor Company.

All information subject to change without notice.

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SERIES 92 SERVICE MANUAL

REVISION NOTIFICATION

Modifications to this manual are announced in the form of Service Information

Bulletins. The bulletins include attachment pages and are posted on the World Wide Web
(www.detroitdiesel.com/svc/sibindex.htm).
Revisions to this manual will be sent marked with a revision bar (see Example 2). Sections
containing revisions will have a third line in the page footer (compare Examples 1 and 2).

All information subject to change without notice.

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 SERIES 92 SERVICE MANUAL

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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1.17 CLUTCH PILOT BEARING ...................................................................... 1-251

1.18 ENGINE DRIVE SHAFT FLEXIBLE COUPLING ..................................... 1-256
1.19 FLYWHEEL HOUSING ............................................................................ 1-264
1.20 PISTON AND PISTON RINGS ................................................................. 1-284
1.21 CONNECTING ROD ................................................................................ 1-308
1.22 CONNECTING ROD BEARINGS ............................................................. 1-326
1.23 CYLINDER LINER .................................................................................. 1-333
1.24 ENGINE BALANCE AND BALANCE WEIGHTS ..................................... 1-347
1.25 GEAR TRAIN AND ENGINE TIMING ...................................................... 1-348
1.26 CAMSHAFTS AND BEARINGS ............................................................... 1-356
1.27 CAMSHAFT GEARS ............................................................................... 1-385
1.28 IDLER GEAR AND BEARING ASSEMBLY .............................................. 1-393
1.29 CRANKSHAFT TIMING GEAR ................................................................ 1-416
1.30 BLOWER DRIVE GEAR AND SUPPORT ASSEMBLY ............................ 1-427
1.31 ACCESSORY DRIVE ............................................................................... 1-445
1.32 BALANCE WEIGHT COVER ................................................................... 1-468
1.A ADDITIONAL INFORMATION .................................................................. 1-473
2 FUEL SYSTEM
2.1 FUEL SYSTEM ....................................................................................... 2-3
2.2 MECHANICAL UNIT INJECTOR ............................................................. 2-7
2.3 ELECTRONIC UNIT INJECTOR .............................................................. 2-55
2.4 FUEL INJECTOR TUBE ........................................................................... 2-66
2.5 ELECTRONIC ENGINE CONTROLS ...................................................... 2-77
2.6 DDEC II .................................................................................................... 2-83
2.7 DDEC III .................................................................................................. 2-89
2.8 DDEC IV .................................................................................................. 2-95
2.9 ELECTRONIC FOOT PEDAL ASSEMBLY ............................................... 2-102
2.10 TURBO BOOST SENSOR ...................................................................... 2-103
2.11 OIL PRESSURE SENSOR ..................................................................... 2-106
2.12 OIL TEMPERATURE SENSOR ............................................................... 2-109
2.13 PULSE WHEEL DDEC III AND II (6V AND 8V ENGINES) ...................... 2-112
2.14 SYNCHRONOUS REFERENCE SENSOR (6V AND 8V) ........................ 2-119
2.15 TIMING REFERENCE SENSOR ............................................................. 2-123
2.16 COOLANT LEVEL SENSOR ................................................................... 2-135
2.17 COOLANT TEMPERATURE SENSOR .................................................... 2-141
2.18 COOLANT PRESSURE SENSOR (12V AND 16V) ................................. 2-143
2.19 FUEL PRESSURE SENSOR ................................................................... 2-145
2.20 FUEL TEMPERATURE SENSOR ............................................................ 2-148
2.21 FUEL PUMP ............................................................................................ 2-151
2.22 FUEL STRAINER AND FUEL FILTER ..................................................... 2-176
2.23 FUEL COOLER ....................................................................................... 2-184
2.24 LIMITING SPEED MECHANICAL GOVERNOR ...................................... 2-187
2.25 LIMITING SPEED MECHANICAL GOVERNOR (VARIABLE
LOW-SPEED) ........................................................................................... 2-252
2.26 LIMITING SPEED MECHANICAL GOVERNOR (VARIABLE HIGH
SPEED) .................................................................................................... 2-266

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2.27 VARIABLE SPEED MECHANICAL GOVERNOR .................................... 2-275

2.28 SG HYDRAULIC GOVERNORS .............................................................. 2-328
2.29 PSG HYDRAULIC GOVERNOR .............................................................. 2-367
2.30 HYDRAULIC GOVERNOR DRIVE ........................................................... 2-376
2.31 HYDRAULIC GOVERNOR SYNCHRONIZING MOTOR .......................... 2-413
2.32 ELECTRONIC GOVERNOR .................................................................... 2-416
2.33 FUEL INJECTOR CONTROL TUBE (NON-DDEC ENGINES) ................ 2-417
2.A ADDITIONAL INFORMATION .................................................................. 2-431
3 LUBRICATING SYSTEM
3.1 LUBRICATION SYSTEM .......................................................................... 3-3
3.2 LUBRICATING OIL PUMP (6V AND 8V ENGINES) ................................ 3-11
3.3 LUBRICATING OIL PUMP (12V AND 16V ENGINES) ............................ 3-35
3.4 LUBRICATING OIL PRESSURE REGULATOR VALVE ........................... 3-49
3.5 LUBRICATING OIL PRESSURE RELIEF VALVE .................................... 3-58
3.6 LUBRICATING OIL FILTERS ................................................................... 3-67
3.7 LUBRICATING OIL COOLER (PLATE TYPE) .......................................... 3-79
3.8 LUBRICATING OIL COOLER (TUBE TYPE) ........................................... 3-93
3.9 LUBRICATING OIL COOLER BYPASS VALVE ........................................ 3-112
3.10 OIL LEVEL DIPSTICK .............................................................................. 3-117
3.11 OIL PAN ................................................................................................... 3-120
3.12 VENTILATING SYSTEM .......................................................................... 3-126
3.A ADDITIONAL INFORMATION .................................................................. 3-131
4 COOLING SYSTEM
4.1 COOLING SYSTEM ................................................................................ 4-3
4.2 WATER PUMP (6V AND 8V ENGINES) .................................................. 4-5
4.3 WATER PUMP (12V AND 16V ENGINES) .............................................. 4-23
4.4 WATER MANIFOLD ................................................................................ 4-35
4.5 THERMOSTAT ........................................................................................ 4-40
4.6 RADIATOR .............................................................................................. 4-50
4.7 COOLANT PRESSURE CONTROL CAP ................................................ 4-63
4.8 ENGINE COOLING FAN .......................................................................... 4-66
4.9 HEAT EXCHANGER ............................................................................... 4-94
4.10 RAW WATER PUMP ................................................................................ 4-102
4.11 COOLANT FILTER AND CONDITIONER ................................................ 4-116
4.A ADDITIONAL INFORMATION .................................................................. 4-123
5 FUEL, LUBRICATING OIL, AND COOLANT
5.1 FUEL ........................................................................................................ 5-3
5.2 LUBRICATING OIL REQUIREMENTS ..................................................... 5-19
5.3 COOLANT ................................................................................................ 5-28
6 AIR INTAKE SYSTEM
6.1 AIR INTAKE SYSTEM ............................................................................. 6-3
6.2 AIR CLEANER ........................................................................................ 6-5
6.3 AIR SEPARATOR FILTER ELEMENT ...................................................... 6-13
6.4 AIR SHUTDOWN HOUSING ................................................................... 6-15
6.5 BLOWER .................................................................................................. 6-27

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6.6 TURBOCHARGER (AIRESEARCH) ........................................................ 6-89

6.7 TURBOCHARGER INTERCOOLER ........................................................ 6-120
6.8 TURBOCHARGER AFTERCOOLER ....................................................... 6-128
6.A ADDITIONAL INFORMATION .................................................................. 6-139
7 EXHAUST SYSTEM
7.1 EXHAUST SYSTEM ................................................................................ 7-3
7.2 EXHAUST MANIFOLD ............................................................................ 7-5
7.3 EXHAUST MANIFOLD (WATER-COOLED) ............................................. 7-11
8 ELECTRICAL EQUIPMENT
8.1 BATTERY-CHARGING ALTERNATOR .................................................... 8-3
8.2 STARTING MOTOR ................................................................................. 8-12
8.3 TACHOMETER DRIVE ............................................................................. 8-15
8.4 INSTRUMENTS ...................................................................................... 8-20
8.5 ENGINE PROTECTIVE SYSTEMS ......................................................... 8-24
8.6 ALARM SYSTEM .................................................................................... 8-45
8.7 OVERSPEED GOVERNOR ..................................................................... 8-52
8.A ADDITIONAL INFORMATION .................................................................. 8-59
9 POWER TAKE-OFF
9.1 POWER TAKE-OFF TORQMATIC CONVERTER .................................... 9-3
10 SPECIAL EQUIPMENT
10.1 AIR COMPRESSOR ............................................................................... 10-3
10.2 ENGINE BLOCK HEATER ....................................................................... 10-9
10.3 TRANSMISSIONS .................................................................................. 10-10
11 OPERATION AND VERIFICATION
11.1 PREPARATION FOR A FIRST TIME START ........................................... 11-3
11.2 STARTING ............................................................................................... 11-8
11.3 RUNNING ................................................................................................. 11-11
11.4 STOPPING .............................................................................................. 11-16
11.5 OPERATING CONDITIONS ..................................................................... 11-18
11.6 ENGINE RUN-IN PROCEDURES ............................................................ 11-52
12 ENGINE TUNE-UP
12.1 ENGINE TUNE-UP ................................................................................. 12-3
12.2 EXHAUST VALVE CLEARANCE ADJUSTMENT .................................... 12-28
12.3 FUEL INJECTOR TIMING ........................................................................ 12-32
12.4 LIMITING SPEED MECHANICAL GOVERNOR INJECTOR RACK
CONTROL ADJUSTMENT (6V AND 8V ENGINES) ............................... 12-35
12.5 LIMITING SPEED MECHANICAL GOVERNOR AND INJECTOR RACK
CONTROL ADJUSTMENT (12V AND 16V ENGINES) ............................ 12-86
12.6 STATIC DOUBLE WEIGHT LIMITING SPEED GOVERNOR GAP
CHECKING AND SETTING PROCEDURE ............................................. 12-118
12.7 LIMITING SPEED MECHANICAL GOVERNOR ADJUSTMENT
(VARIABLE LOW-SPEED) ....................................................................... 12-129
12.8 LIMITING SPEED MECHANICAL GOVERNOR FAST IDLE CYLINDER 12-139
12.9 GOVERNOR SETTINGS FOR "TT" ENGINES ........................................ 12-143

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12.10 VARIABLE SPEED MECHANICAL GOVERNOR INJECTOR RACK

CONTROL ADJUSTMENT (6V AND 8V ENGINES) ............................... 12-173
12.11 VARIABLE SPEED MECHANICAL GOVERNOR AND INJECTOR RACK
CONTROL ADJUSTMENT (12V AND 16V ENGINES) ............................ 12-186
12.12 SG VARIABLE SPEED HYDRAULIC GOVERNOR INJECTOR RACK
CONTROL ADJUSTMENT (6V AND 8V ENGINES) ............................... 12-204
12.13 SG VARIABLE SPEED HYDRAULIC GOVERNOR INJECTOR RACK
CONTROL ADJUSTMENT (12V AND 16V) ............................................. 12-223
12.14 GOVERNORS WITH SYNCHRONIZING MOTOR ................................... 12-243
12.15 SUPPLEMENTARY GOVERNING DEVICE ADJUSTMENT .................... 12-244
12.16 POWER CONTROL DEVICE ................................................................... 12-248
12.17 THROTTLE DELAY MECHANISM ADJUSTMENT .................................. 12-251
12.18 FUEL MODULATOR ................................................................................ 12-264
13 PREVENTIVE MAINTENANCE
13.1 PREVENTIVE MAINTENANCE ITEMS DESCRIPTION .......................... 13-5
13.2 MAINTENANCE OF VEHICLE ENGINE .................................................. 13-6
13.3 MAINTENANCE OF STATIONARY AND INDUSTRIAL ENGINE ............ 13-12
13.4 MAINTENANCE OF PLEASURE CRAFT MARINE ENGINES ................ 13-16
13.5 LUBRICATING OIL ................................................................................... 13-19
13.6 OIL PRESSURE ...................................................................................... 13-26
13.7 LUBRICATING OIL FILTER ...................................................................... 13-27
13.8 FUEL STRAINER AND FILTER ............................................................... 13-29
13.9 FUEL TANK ............................................................................................. 13-32
13.10 FUEL CONTAMINATION .......................................................................... 13-33
13.11 FUEL LINES AND FLEXIBLE HOSES ..................................................... 13-34
13.12 COOLING SYSTEM ................................................................................ 13-36
13.13 WATER PUMP ........................................................................................ 13-49
13.14 COOLANT FILTER .................................................................................. 13-50
13.15 COOLANT FILTER/INHIBITOR PRECHARGE ELEMENT ...................... 13-51
13.16 RADIATOR .............................................................................................. 13-53
13.17 TURBOCHARGER AND EXHAUST CONNECTIONS ............................. 13-54
13.18 DRIVE BELTS ......................................................................................... 13-58
13.19 BATTERY ................................................................................................. 13-65
13.20 BATTERY CHARGING ALTERNATOR ..................................................... 13-68
13.21 ENGINE AND TRANSMISSION MOUNTS .............................................. 13-70
13.22 ENGINE TUNE-UP ................................................................................. 13-71
13.23 BLOWER BYPASS VALVE ....................................................................... 13-72
13.24 TACHOMETER DRIVE ............................................................................. 13-73
13.25 AIR COMPRESSOR ............................................................................... 13-74
13.26 THROTTLE AND CLUTCH CONTROLS ................................................. 13-75
13.27 AIR BOX DRAIN TUBE ............................................................................ 13-76
13.28 AIR BOX CHECK VALVES ....................................................................... 13-77
13.29 SHUTTER OPERATION ......................................................................... 13-78
13.30 GOVERNOR, OVERSPEED GOVERNOR .............................................. 13-79
13.31 THROTTLE DELAY FUEL MODULATOR ................................................ 13-80
13.32 FAN HUB .................................................................................................. 13-81

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13.33 FAN (THERMO-MOUNTED) ................................................................... 13-83

13.34 THERMOSTATS AND SEALS .................................................................. 13-84
13.35 BLOWER SCREEN ................................................................................. 13-85
13.36 FUEL INJECTORS AND VALVE CLEARANCE ....................................... 13-87
13.37 VIBRATION DAMPER .............................................................................. 13-88
13.38 STARTING MOTOR ................................................................................. 13-89
13.39 EXHAUST SYSTEM ................................................................................ 13-91
13.40 CRANKCASE BREATHER (EXTERNALLY MOUNTED) ......................... 13-92
13.41 CRANKCASE BREATHER (INTERNALLY MOUNTED) .......................... 13-93
13.42 ENGINE (STEAM CLEAN) ....................................................................... 13-94
13.43 POWER TAKE-OFF ................................................................................ 13-95
13.44 TORQMATIC CONVERTER ..................................................................... 13-97
13.45 REDUCTION GEAR ................................................................................. 13-99
13.46 TRANSIT COACH CONVERTER MUFFLER ........................................... 13-101
13.47 AIR CLEANER ........................................................................................ 13-103
13.48 AIR SYSTEM .......................................................................................... 13-106
13.49 AIR SEPARATOR FILTER ELEMENT ...................................................... 13-107
13.50 AIR SHUTDOWN VALVE ......................................................................... 13-111
13.51 COOLING SYSTEM (MARINE) ............................................................... 13-112
13.52 HEAT EXCHANGER CHANGEOUT INTERVAL ...................................... 13-113
13.53 HEAT EXCHANGER ELECTRODES AND CORE (RAW WATER
SYSTEM ZINCS) ..................................................................................... 13-116
13.54 RAW WATER PUMP ................................................................................ 13-118
13.55 FUEL AND BOOST COOLERS ............................................................... 13-121
13.56 TORQMATIC MARINE GEAR (6V AND 8V) ............................................ 13-122
13.57 MARINE GEAR (TWIN DISC 16V) .......................................................... 13-124
13.58 CLUTCH ACTUATOR (DDEC MARINE) .................................................. 13-126
14 STORAGE
14.1 PREPARING ENGINE FOR STORAGE ................................................... 14-3
14.2 TEMPORARY ENGINE STORAGE (30 DAYS OR LESS) ....................... 14-4
14.3 RESTORING A TEMPORARILY STORED ENGINE (30 DAYS OR
LESS) ....................................................................................................... 14-6
14.4 EXTENDED ENGINE STORAGE (MORE THAN 30 DAYS) .................... 14-7
14.5 RESTORING AN EXTENDED STORAGE ENGINE (MORE THAN 30
DAYS) ....................................................................................................... 14-13
14.6 STORAGE OF BATTERY ......................................................................... 14-16
INDEX ................................................................................................. Index-1

All information subject to change without notice.

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ENGINE EXHAUST

Consider the following before servicing engines:

Diesel engine exhaust and some of its constituents are

known to the State of California to cause cancer, birth
defects, and other reproductive harm.
Always start and operate an engine in a well ventilated
area.
If operating an engine in an enclosed area, vent the
exhaust to the outside.
Do not modify or tamper with the exhaust system or
emission control system.

Please note this caution and remember:

Always start and operate the engine in a well ventilated area.
If in an enclosed area, vent the exhaust to the outside.
Do not modify or tamper with the exhaust system.For accurate dynamometer readings
during a engine run-in, the chassis dynamometer room must be properly ventilated.

Diesel engine exhaust and some of its constituents are

known to the State of California to cause cancer, birth
defects, and other reproductive harm.
Always start and operate an engine in a well ventilated
area.
If operating an engine in an enclosed area, vent the
exhaust to the outside.
Do not modify or tamper with the exhaust system or
emission control system.

All information subject to change without notice.

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All information subject to change without notice.

x 6SE379 0303 Copyright © 2003 DETROIT DIESEL CORPORATION
GENERAL INFORMATION

Section Page
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
SERIES 92 SERVICE MANUAL

DECIMAL AND METRIC EQUIVALENTS ................................................... 30

SPECIFICATIONS ..................................................................................... 30

All information subject to change without notice.

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SCOPE AND USE OF THIS MANUAL

This manual covers the basic V-92 diesel engines built by the Detroit Diesel Corporation.
Complete instructions on operation, adjustment (tune-up), preventive maintenance, and
lubrication and repair (including complete overhaul) are covered. Basic maintenance and overhaul
procedures are common to all V-92 engines and apply to all engine models.
The manual is divided into numbered sections. The first section covers the engine (less major
assemblies). The following sections cover a complete system such as the fuel system, lubrication
system or air system. Each section is divided into subsections containing complete maintenance
and operating instructions for a specific subassembly on the engine. Each section begins with a
table of contents. Pages and illustrations are numbered consecutively within each section.
Information can be located using the table of contents at the front of the manual or the table of
contents at the beginning of each section. Information on specific subassemblies within the major
section is listed immediately following the section title.

SAFETY PRECAUTIONS

The following safety measures are essential when working on the Series 92 engine.
Please note this caution and remember:
Always start and operate the engine in a well ventilated area.
If in an enclosed area, vent the exhaust outside.
Do not modify or tamper with the exhaust system.

Diesel engine exhaust and some of its constituents are

known to the State of California to cause cancer, birth
defects, and other reproductive harm.
Always start and operate an engine in a well ventilated
area.
If operating an engine in an enclosed area, vent the
exhaust to the outside.
Do not modify or tamper with the exhaust system or
emission control system.

Stands

Safety stands are required in conjunction with hydraulic jacks or hoists. Do not rely on either
the jack or the hoist to carry the load. When lifting an engine, ensure lifting device is fastened
securely. Ensure that the item to be lifted does not exceed the capacity of the lifting device.

Glasses

Select appropriate safety glasses for the job. It is especially important to wear safety glasses when
using tools such as hammers, chisels, pullers, or punches.

All information subject to change without notice.

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Welding

Wear welding goggles and gloves when welding or using an acetylene torch. Ensure that a metal
shield separates the acetylene and oxygen that must be chained to a cart.

All information subject to change without notice.

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To avoid injury from arc welding, gas welding, or cutting,

wear required safety equipment such as an arc welder’s
face plate or gas welder’s goggles, welding gloves,
protective apron, long sleeve shirt, head protection,
and safety shoes. Always perform welding or cutting
operations in a well-ventilated area. The gas in
oxygen/acetylene cylinders used in gas welding and
cutting is under high pressure. If a cylinder should fall
due to careless handling, the gage end could strike an
obstruction and fracture, resulting in a gas leak leading to
fire or an explosion. If a cylinder should fall resulting in
the gage end breaking off, the sudden release of cylinder
pressure will turn the cylinder into a dangerous projectile.
Observe the following precautions when using
oxygen/acetylene gas cylinders:
Always wear required safety shoes.
Do not handle tanks in a careless manner or with greasy
gloves or slippery hands.
Use a chain, bracket, or other restraining device at all
times to prevent gas cylinders from falling.
Do not place gas cylinders on their sides, but stand
them upright when in use.
Do not drop, drag, roll, or strike a cylinder forcefully.
Always close valves completely when finished welding
or cutting.

To avoid injury from fire, keep all potential ignition sources

away from diesel fuel, open flames, sparks, and electrical
resistance heating elements. Do not smoke when refueling.

Work Place
Organize your work area, and keep it clean. A fall could result in a serious injury. Eliminate
the possibility of a fall by:
Wiping up oil spills.
Keeping tools and parts off the floor.
After servicing or adjusting the engine:
Install all safety devices, guards, or shields.
Ensure that all tools and service equipment are removed from the engine.

All information subject to change without notice.

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Clothing

Wear safe work clothes that fit and are in good condition. Work shoes are sturdy and rough-soled.
Bare feet, sandals, or sneakers are not acceptable foot wear when adjusting and/or servicing an
engine. Do not wear the following when working on an engine:

To avoid injury when working near or on an operating

engine equipped with electric fans, remove loose items of
clothing, jewelry; tie back or contain long hair that could
be caught in any moving part causing injury. Electric fans
may start without warning.

Rings
Wrist watches
Loose fitting clothing
Any of these items could catch on moving parts causing serious injury.

Power Tools

Do not use defective portable power tools. Check for frayed cords prior to using the tool. Ensure
that all electric tools are grounded. Defective electrical equipment and improper use of electrical
equipment can cause severe injury.

To avoid injury from electrical shock, follow OEM furnished

operating instructions prior to usage.

Air

Recommendations regarding the use of compressed air are indicated throughout the manual
with the following:

All information subject to change without notice.

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To avoid injury from flying debris when using compressed

air, wear adequate eye protection (face shield or safety
goggles) and do not exceed 40 psi (276 kPa) air pressure.

Too much air can rupture or in some other way damage a component and create a hazardous
situation that can lead to personal injury. Use only approved air blow guns that do not exceed
276 kPa (40 lb/in.2). Wear safety glasses or goggles. Use proper shielding to protect everyone in
the work area.

Fluids and Pressure

Be extremely careful when dealing with fluids under pressure.

To avoid injury from penetrating fluids, do not put your

hands in front of fluid under pressure. Fluids under
pressure can penetrate skin and clothing.

Fluids under pressure can penetrate the skin. These fluids can infect a minor cut or opening in
the skin. If injured, see a doctor immediately.

Fuel

Keep the hose and nozzle or the funnel and container in contact with the metal of the fuel tank
when refueling to avoid the possibility of an electric spark igniting the fuel.
The following cautions should be followed when filling a fuel tank:

All information subject to change without notice.

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To avoid injury from fire, do not overfill the fuel tank.

To avoid injury from fire, keep all potential ignition sources

away from diesel fuel, open flames, sparks, and electrical
resistance heating elements. Do not smoke when refueling.

To avoid injury from fire, keep all potential ignition sources

away from diesel fuel, open flames, sparks, and electrical
resistance heating elements. Do not smoke when refueling.

Batteries

Electrical storage batteries emit highly flammable hydrogen gas when charging and continue to
do so for some time after receiving a steady charge.

To avoid injury from battery explosion or contact with

battery acid, work in a well-ventilated area, wear protective
clothing, and avoid sparks or flames near the battery.
Always establish correct polarity before connecting cables
to the battery or battery circuit. If you come in contact with
battery acid:
Flush your skin with water.
Apply baking soda or lime to help neutralize the acid.
Flush your eyes with water.
Get medical attention immediately.

Always disconnect the battery cable before working on the electrical system.

All information subject to change without notice.

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To avoid injury from accidental engine startup while

servicing the engine, disconnect/disable the starting
system.

Disconnect the batteries or disable an air starter when working on the engine to prevent accidental
starting.

Fire
Keep a charged fire extinguisher within reach. Ensure the correct type of extinguisher is used
for the situation.

Cleaning Agent

Avoid the use of carbon tetrachloride as a cleaning agent because of the harmful vapors that it
releases. Ensure work area is adequately ventilated. Use protective gloves, goggles or face
shield, and apron.

Working on a Running Engine

When working on a running engine, accidental contact with the hot exhaust manifold can cause
severe burns. Remain alert to the location of the rotating fan, pulleys and belts. Avoid making
contact across the two terminals of a battery which can result in severe arcing, or battery explosion.

To avoid injury from hot surfaces, allow engine to cool

before removing any component. Wear protective gloves.

To avoid injury, use care when working around moving belts

and rotating parts on the engine.

Start Attempts

Observe the following caution when working with mineral spirits or mineral spirit-based solvents.

All information subject to change without notice.

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