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.) |
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.) |
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.) |
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.) |
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.) |
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) |
Torque Values
Tighten cylinder head bolts following the assembly steps listed:
- Lubricate bolt threads, bolt head seating areas and washers with clean engine oil.
- Tighten bolts in three (3) stages. See Figure
"Sequence for Tightening Cylinder Head Bolts"
.
Figure 1. Sequence for Tightening Cylinder Head Bolts
SERVICE TOOLS
Tools required for maintenance and repair:
Description |
Tool |
Sled Gage |
|
Valve Spring Tester |
|
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 |
Series 40E Service Manual - 6SE410 |
Generated on 10-13-2008 |