Series 40E

Torque Values

Additional Information

SPECIFICATIONS

The following specifications apply to the Series 40E engine:‪

Series 40E Engine Components

Specifications

Exhaust Valves

Stem Diameter‪

9.423 mm (0.3710 in.) 9.441 mm (0.3717 in.)‪

Stem to Guide Clearance (Max. Allowable Before Replacement)‪

0.15 mm (0.006 in.)‪

Face to Stem Run-out (TIR Max.)‪

0.038 mm (0.0015 in.)‪

Valve Face Angle‪

455 - 00' - 455 - 15'‪

Valve Face Margin (Min.)‪

0.64 mm (0.045 in.)‪

Valve Lash‪

0.64 mm (0.025 in.)‪

Intake Valves

Stem Diameter‪

9.444 mm (0.3718 in.) 9.461 mm (0.3725 in.)‪

Stem to Guide Clearance (Max. Allowable Before Replacement)‪

0.15 mm (0.006 in.)‪

Face to Stem Run-out (TIR Max.)‪

0.038 mm (0.0015 in.)‪

Valve Face Angle‪

305 - 00' - 305 - 15'‪

Valve Face Margin (Min.)‪

2.24 mm (0.088 in.)‪

Valve Lash‪

0.64 mm (0.025 in.)‪

Cylinder Head

Valve Guide Type‪

Replaceable‪

Valve Guide Length (overall)‪

66.294 ± 0.508 mm (2.610 ± 0.020 in.)‪

Valve Guide Bore Diameter in Cylinder Head for Valve Guide Insert‪

15.844 mm (0.6238 in.) 15.880 mm (0.6252 in.)‪

Service Valve Guide O.D‪

15.898 mm (0.6259 in.) 15.918 mm (0.6267 in.)‪

Service Valve Guide I.D. (After Assembly)‪

9.500 mm (0.3740 in.) 9.525 mm (0.3750 in.)‪

Service Valve Guide Interference Fit Dimension‪

0.018 mm (0.0007 in.) 0.074 mm (0.0029 in.‪

Valve Guide Bore Out-of-Round (Max.)‪

0.05 mm (0.002 in.)‪

Valve Guide Bore Taper (Max.)‪

0.13 mm (0.005 in.)‪

Valve Guide Height from Cylinder Head Spring Pocket (Intake)‪

22.05 mm (0.868 in.) 22.56 mm (0.888 in.)‪

Valve Seat Insert Angle (Intake)‪

305 - 00' - 305 - 15'‪

Valve Seat Insert Angle (Exhaust)‪

455 - 00' - 455 - 15'‪

Valve Seat Width (Intake & Exhaust)‪

1.91 mm (0.075 in.) 2.16 mm (0.085 in.)‪

Valve Seat Run-out (TIR Max.)‪

0.05 mm (0.002 in.)‪

Intake Valve Seat O. D.‪

0.05 mm (0.002 in.) Oversize‪

46.304 mm (1.823 in.)‪

0.381 mm (0.015 in.) Oversize‪

46.634 mm (1.836 in.)‪

Exhaust Valve Seat O.D.‪

0.05 mm (0.002 in.) Oversize‪

46.050 mm (1.813 in.)‪

0.38 mm (0.015 in.) Oversize‪

46.380 mm (1.826 in.)‪

Valve Seat Insert Cylinder Head Counterbore Diameter Intake: Standard Size 0.05 mm (0.002 in.) 0.381 mm (0.015 in.) Exhaust: Standard Size 0.05 mm (0.002 in.) 0.381 mm (0.015 in.)‪

46.253 mm (1.821 in.) 46.304 mm (1.813 in.) 46.634 mm (1.836 in.) 46.0 mm (1.811 in.) 46.050 mm (1.813 in.) 46.380 mm (1.826 in.)‪

Valve Head Recession Relative to Deck Surface (Intake & Exhaust)‪

0.00 mm (0.000 in.) 0.36 mm (0.014 in.)‪

Cylinder Head Surface Flatness‪

0.10 mm (0.004 in.) in 229 mm (9 in.)‪

Deck-to-Deck Dimension‪

(Head Thickness) (New)‪

128.27 mm (5.050 in.) 128.78 mm (5.070 in.)‪

Minimum Deck-to-Deck Dimension After Rework‪

128.02 mm (5.040 in.)‪

Table 1. Series 40E Engine Specifications

Crankshaft

Specifications

Type‪

Steel Forging, Induction Hardened, Grindable‪

Main Bearing Journal Diameter:‪

Standard Size‪

89.8 ± .0152 mm (3.535 ± 0.006 in.)‪

0.254 mm (.010 in.) Undersize‪

89.5 ± .0152 mm (3.525 ± 0.006 in.)‪

0.508 mm (.020 in.) Undersize‪

89.3 ± .0152 mm (3.515 ± 0.006 in.)‪

0.762 mm (.030 in.) Undersize‪

89.0 ± .0152 mm (3.505 ± 0.006 in.)‪

Main Bearing Width (Except Rear Thrust)‪

33 ± 0.254 mm (1.286 ± 0.010 in.)‪

Main Bearing Journal Max. Out-of-Round‪

0.05 mm (0.002 in.)‪

Main Bearing Thrust Face Run-out (TIR Max)‪

0.025 mm (0.001 in.)‪

Main Bearing Journal Taper (Max/in.)‪

0.0711 mm (0.0028 in.)‪

Main Bearing Journal Fillet Radius‪

5.72/1.27 mm (0.225/0.050 in.)‪

Rod Journal Fillet Radius‪

5.72/1.27 mm (0.225/0.050 in.)‪

Rear Oil Seal Journal Run-out (Max)‪

0.076 mm (0.003 in.)‪

Damper Mounting Area Run-out (Max)‪

0.013 mm (0.0005 in.)‪

Flywheel Mounting Surface Run-out (Max)‪

0.05 mm (0.0002 in.)‪

Number of Main Bearings‪

7‪

Thrust Taken By‪

Rear Main Thrust Bearing Journal Length‪

Thrust Bearing Journal Length‪

Standard Size to 0.508 mm (0.020 in.) Undersize‪

34.4 ± 0.0254 mm (1.3545 ± 0.010 in.)‪

0.762 mm (0.030 in.) Undersize‪

34.4 ± 0.0254 mm (1.3545 ± 0.010 in.)‪

Main Bearing to Crankshaft Running Clearance‪

0.127/0.046 mm (0.0050/0.0018 in.)‪

Connecting Rod Journal Diameter Standard Size‪

80.0 ± 0.0152 mm (3.1500 ± 0.0006 in.)‪

0.254 mm (0.010 in.) Undersize‪

79.7 ± 0.0152 mm (3.1400 ± 0.0006 in.)‪

0.508 mm (0.020 in.) Undersize‪

79.5 ± 0.0152 mm (3.1300 ± 0.0006 in.)‪

0.762 mm (0.030 in.) Undersize‪

79.2 ± 0.0152 mm (3.1200 ± 0.0006 in.)‪

Connecting Rod Bearing Width‪

35.2 mm (1.385 in.)‪

Connecting Rod Journal Max Out-of-Round‪

0.0064 mm (0.00025 in.)‪

Connecting Rod Journal Taper (Max/in.)‪

0.0069 mm (0.00027 in.)‪

Connecting Rod Bearing to Crankshaft Running Clearance‪

0.127-0.046 mm (0.0050-0.0018 in.)‪

Crankshaft Flange O.D.‪

141 mm (5.550 in.)‪

Crankshaft End Play‪

0.152-0.305 mm (0.006-0.012 in.)‪

Crankshaft End Play Max Wear Limit‪

0.508 mm (0.020 in.)‪

Rod to Crankshaft Side Clearance‪

0.304 ± 0.1143 mm (0.12 ± 0.0045 in.)‪

Crankshaft Gear Backlash‪

0.076-0.406 mm (0.003-0.016 in.)‪

Flywheel Run-out (Face Run-out): Flat Flywheel for Clutch Applications:‪

Face Run-out Measured at 177.8 mm (7.0 in.) Radius‪

0.18 mm (0.007 in.)‪

Pot Flywheel for Clutch Applications: Face Run-out Measured at 165.1 mm (6.5 in.) Radius‪

0.165 mm (0.0065 in.)‪

Face Run-out (Mounting Surface for Clutch Cover Plate): Measured at 190.5 mm (7.5 in.) Radius Flywheel Concentricity (Radial Run-out)‪

0.19 mm (0.0075 in.)‪

Flat Flywheel for Clutch Applications: Radial Run-out Measured at Clutch Mounting Holes‪

0.20 mm (0.008 in.)‪

Pot Flywheel for Clutch Applications: Radial Run-out of Clutch Pilot Bore (I.D. of Pot Flywheel)‪

0.13 mm (0.005 in.)‪

Flywheel Resurfacing (for Clutch Applications): Requires Measurement from Crankshaft Mounting Surface of Flywheel-to-Clutch Surface of Flywheel‪

NOTE: Do not machine beyond minimum dimension shown.‪

Flat Flywheel‪

36.3 mm (1.430 in.)‪

Pot Flywheel‪

39.4 mm (1.550 in.)‪

Flywheel Housing Bore Concentricity*‪

SAE#1=0.30 mm (0.012 in.), SAE#2=0.28 mm (0.011 in.)‪

Flywheel Housing Face Run-out*‪

SAE#1=0.30 mm (0.012 in.), SAE#2=0.28 mm (0.011 in.)‪

Vibration Damper Max Allowable Member Misalignment‪

1.5 mm (0.060 in.)‪

Vibration Damper Wobble (Max)‪

1.5 mm (0.060 in.)‪

Crankcase Deck Flatness‪

0.076 mm (0.003 in.)‪

Crankcase Deck Finish (Micro inches)‪

125 AA‪

Centerline of Main Bearing Bore to Head Deck‪

368.3 ± 0.0381 mm (14.5 ± 0.0015 in.)‪

Crankcase Main Bearing Bore Diameter‪

97.8 ± 0.0127 mm (3.8491 ± 0.0005 in.)‪

Table 2. Crankshaft Specifications

Note: * Must be measured per SAE specification J1033.

Crankcase

Specifications

Tappet Bore Diameter‪

28.511/28.549 mm (1.1225/1.1240 in.)‪

Valve/Roller Tappet O.D.‪

28.435/28.448 mm (11.1195/1.1200 in.)‪

Oil Jet Tube Bore Diameter (Spray Hole Dia.)‪

1.22/1.24 mm (0.048/0.049 in.)‪

Counterbore Dimension in Crankcase‪

8.86 ± 0.025/at 132 mm (0.349 ± 0.001/at 0.635 gage dia.‪

Maximum Allowable Variation of Counterbore Depth (Between Four Points)‪

0.025 mm (0.0001)‪

Max Cylinder Sleeve Counterbore Allowable Depth‪

9.25 mm (0.364 in.)‪

Protrusion Above Crankcase‪

0.050 to 0.127 mm (0.002 to 0.005 in.)‪

Main Bearing Type‪

Precision Replaceable‪

Material‪

Steel-Backed Copper/Lead‪

Thrust Taken By‪

No. 7 Rear‪

Cap Attachment‪

2 Bolts per Cap‪

Camshaft Bushing Bore Diameter in Crankcase: Front, Intermediate Front, Intermediate Rear , Rear‪

63.513/63.550 mm (2.5005/2.5020 in.) 63.005/63.043 mm (2.4805/2.4820 in.) 62.496/62.535 mm (2.4605/2.4620 in.) 61.988/62.026 mm (2.4405/2.4420 in.)‪

Table 3. Crankcase Specifications

Valve Springs

Specifications

Intake:

Number of Springs per Valve‪

1‪

Identification Color Strip‪

Blue‪

Valve Spring Free Length‪

58.22 mm (2.292 in.)‪

Test Length (Valve Closed)‪

51 mm (2.007 in.)‪

Test Load (Valve Closed)‪

333-369 N (75-83 lbs)‪

Test Length (Valve Open)‪

38 mm (1.497 in.)‪

Test Load (Valve Open)‪

921-965 N (207-217 lbs)‪

Wire Diameter‪

5.26 mm (.207 in.)‪

Exhaust:

Number of Springs per Valve‪

1‪

Identification Color Strip‪

White‪

Valve Spring Free Length‪

62.18 mm (2.448 in.)‪

Test Length (Valve Closed)‪

50.29 mm 1.980 in.)‪

Table 4. Valve Springs

Camshaft Position Sensor

Specifications

Location‪

Front Cover‪

Operating Actuator Speed‪

15 to 2000 r/min‪

CMP Sensor Clearance Air Gap:‪

-40°C to +130°C (-40°F to 54°F)‪

Crankshaft rotated in a clockwise direction‪

29.90 ± 0.356 mm (1.177 ± 0.014 in.)‪

Crankshaft rotated in a counterclockwise direction‪

29.67 ± 0.356 mm (1.168 ± .014 in.)‪

Table 5. Camshaft Position Sensor

Component

Torque Value

Cylinder Head Bolts

-‪

Fuel Injector Hold Down Clamp Mounting Bolt‪

14 N·m (120 lb·in.)‪

Fuel Injector Hold Down Clamp Shoulder Bolt‪

14 N·m (120 lb·in.)‪

High Pressure Oil Hose Nut‪

26 N·m (19 lb·ft)‪

Injection Control Pressure Sensor ( Apply Loctite ® #277 to threads prior to installation )‪

35 N·m (26 lb·ft)‪

Injection Pressure Regulator Valve‪

56 N·m (41 lb·ft)‪

Supply Manifold Mounting Bolt‪

55 N·m (41 lb·ft)‪

Supply Manifold End Plug‪

81 N·m (60 lb·ft)‪

Supply Manifold 3-way Fitting Nut‪

35 N·m (26 lb·ft)‪

Supply Manifold Fuel Return Nut‪

27 N·m (20 lb·ft)‪

Valve Adjusting Screw Nut‪

27 N·m (20 lb·ft)‪

Connecting Rod Bolt‪

155 N·m (115 lb·ft)‪

Crankshaft Main Bearing Cap Bolts‪

217 N·m (160 lb·ft)‪

Vibration Damper Pulley Retainer Bolts‪

136 N·m (100 lb·ft)‪

Flywheel Bolts‪

136 N·m (100 lb·ft)‪

Flywheel Housing Mounting Bolts‪

108 N·m (80 llb·ft)‪

Oil Pan Mounting Bolts‪

23 N·m (17 lb·ft)‪

Oil Pan Drain Plug‪

68 N·m (50 lb·ft)‪

Oil Pick-up Tube Bolts‪

21 N·m (15 lb·ft)‪

Oil Pick-up Tube Bracket Bolt‪

21 N·m (15 lb·ft)‪

Oil Level Gage Tube Clamp‪

3 N·m (30 lb·in.)‪

Front Engine Mounting Bracket Mounting Bolts‪

385 N·m (284 lb·ft)‪

Idler Gear Retaining Bolt‪

325 N·m (240 lb·ft)‪

Special Mounting Nut (PTO Application Only)‪

108 N·m (80 lb·ft)‪

Table 6. Torque Values, Engine

Torque Values

Tighten cylinder head bolts following the assembly steps listed:‪

  1. Lubricate bolt threads, bolt head seating areas and washers with clean engine oil.
  2. Tighten bolts in three (3) stages. See Figure "Sequence for Tightening Cylinder Head Bolts" .
    Click to see this graphic in a separate window

    Figure 1. Sequence for Tightening Cylinder Head Bolts

SERVICE TOOLS

Tools required for maintenance and repair:‪

Description

Tool

Sled Gage‪

J 22273-01

Valve Spring Tester‪

J 22738-02

Piston Groove Wear Measuring Tool‪

J 29511

Cylinder Liner Remover Tool (Screw Type)‪

J 35791

Pressure Test Kit (Engine Field Test Kit)‪

J 39257

Crankshaft - Front Oil Seal Wear Sleeve Installer‪

J 39266

Orifice Restrictor Tool‪

J 39267

Valve Guide Installer‪

J 39292

Valve Seat Insert Installer‪

J 39535

Camshaft Bushing Service Set‪

J 39537

Crankshaft - Rear Oil Seal Sleeve Installer‪

J 41163

Valve Guide Removal Tool‪

J 41164

Lower Idler Gear /Nut Socket, 3/4 in. (20 mm) 12 pt.‪

J 41167

Wear Sleeve Removal Tool‪

J 42944

Fuel Injector Sleeve Remover‪

J 42945

Fuel Injector Nozzle Sleeve Installer‪

J 42947

Engine Harness Repair Kit‪

J 42948

Terminal Release Tool Kit‪

J 42949

Cylinder Sleeve Holding Adaptors‪

J 43095

Guide Stud Set‪

J 43096

Oil Cooling Plate‪

J 43097

Cylinder Head Magnet Intake Shield‪

J 43099

Valve Guide Installer‪

J 43100

CEC Breakout Box‪

J 43102

ICP Breakout T Harness‪

J 43103

ICP Adaptor Plug Kit‪

J 43104

Universal Valve Seat Extractor‪

PT 6391

Valve Seat Extractor Collet‪

PT 6390-45

Table 7. Service Tools


Series 40E Service Manual - 6SE410
Generated on 10-13-2008

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