Detroit Diesel Engine Series 92 All models 9.0 litre (V6), 12.1 litre (V8), 18.1 litre (V12) and 24.1 litre (V16) Service Repair Manual
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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.
Models Coverd :
Series 92 All models 9.0 litre (V6), 12.1 litre (V8), 18.1 litre (V12) and 24.1 litre (V16)
- DDEC
- DDEC I
- DDEC II
- DDEC III
Contents :
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
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
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
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 POWERTAKE-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
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
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
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