S40e MASTER

INTRODUCTION
Series
s 40E
Overhaul / Electroniics and Diagnostics
Cou
urse
Series 40E
Left Side View
Series 40E25ST0041/2
2/15 99
Series 40E
Right Side View
2/15 99
Series 40E
Front View
2/15 99
Series 40E
Rear View
2/15 99
Series 40E
Engine Cutaway
2/15 99
Series 40E
Emission Identification
2/15 99
Series 40E
Se
erial Number Description
Engine Identifying Code:
WN1234
N XXXXXXX
WL == 7.6TA
WN == 8.7TA
Country of Origin:
U.S.A.
USA
Starting Engine Serial Nu

umber:
(Sequence Number)
Stamped on pad located on crankcase left side

2/15 99
THE FOUR
R STROKE
CYC
CLE
FO
OUR STROKE CYCLE
2/15 99
INDUCT
TION,COMPRESSION,
POWER,EXHAUST.
2/15 99
GENE
ERAL
CONSTR
RUCTION
Series 40E
C
Cylinder
Head Overview
2/15 99
Series 40E
Intake Port Protection
2/15 99
Series 40E
C
Cylinder
Head Assembly
Fuel Supply
High Pressure Oil
2/15 99
Series 40E
I
Injector
Sleeve Location
2/15 99
Series 40E
Injector Sleeve Tools
2/15 99
Series 40E
Injec
ctor Sleeve Replacement
2/15 99
Series 40E
Supply Manifold
2/15 99
Series 40E
Supply Manifold Gasket
2/15 99
Series 40E
Cylinder Head Dye Penetrant
P
Crack Check
2/15 99
Series 40E
Flatness Check
2/15 99
Series 40E
Cylinderr Head Thickness Check
2/15 99
Series 40E
Valve Guide Removal
2/15 99
Series 40E
Valve Guide Installation
2/15 99
Series 40E
Valve
e Seat Removal (Stage 1)
2/15 99
Series 40E
Valve
e Seat Removal (Stage 2)
2/15 99
Series 40E
Valve Seat Installation
2/15 99
Series 40E
Valve Assembly
2/15 99
Test valve rotator
2/15 99
Series 40E
Valve Stem Seals
2/15 99
Series 40E
Valve Components
2/15 99
Series 40E
Valve Depth Check
2/15 99
Series 40E
C
Cylinder
Head Overview
2/15 99
Series 40E
Rocker Arm Clearance
2/15 99
Rocker Lever B
Bushing Measurement
2/15 99
Series 40E
Valve Rotator
2/15 99
Valv
ve Assembly Installed
2/15 99
Piston 7.6
7 6 Liter Engine
2/15 99
Piston/Connecting Rod
d Assembly 7.6L
7 6L Engine
2/15 99
Piston Cro
own with Skirt and Pin
2/15 99
PISTON ASSEMBL
LY- 8.7
LY
8 7 LITER ENGINE
2/15 99
Piston Ring Formation
2/15 99
Piston Gage Pins
2/15 99
Piston Piin Bushing Clearance
2/15 99
Cylinder Block
2/15 99
Cylinder Liners
2/15 99
Series 40E
Cylinder Liner
L
Bore Measurement
2/15 99
Crankcas
se Counterbore Depth
2/15 99
Series 40E
L
Liner
Flange Bore Depth
2/15 99
Counterboring Tool
2/15 99
Lubricate O Rings
2/15 99
Liner Protrusion Check
2/15 99
Crankshaft
2/15 99
Crankshaft Journal
2/15 99
Main Bearing Shells
2/15 99
Measure
e Crankshaft Journals
2/15 99
Series 40E
Crrankshaft Gear Removal
2/15 99
Rear Seal Wearr Sleeve Replacement
2/15 99
Install Rear Oil Seal
2/15 99
Rear O
Oil Seal Installer Tool
2/15 99
Re
ear Oil Seal Alignment
2/15 99
Flywheel Installation
2/15 99
Camshaft
2/15 99
Mea
asure Camshaft Lobe
2/15 99
Ca
amshaft Bushing Tool
2/15 99
Camsha
aft Bushing Positions
2/15 99
Camsh
haft Rear O Ring Seal
2/15 99
Roller Tappets
2/15 99
Oil Gallery End Plug
2/15 99
Series 40E
Timing Gear Assembly
2/15 99
Series 40E
Crankcase Front Cover (Front Half)
2/15 99
Front Damper Pulley
2/15 99
Electric Heat Pad T

To Install Front Pulley
2/15 99
THE AIR SYSTEM
F
Features
And Benefits
2/15 99
Series 40E
Combustion Air Flow
2/15 99
Charge Air Cooler
2/15 99
Series 40E
Intake Manifold / Rocker Cover
2/15 99
Exhaust Manifold
2/15 99
Wasttegated Turbocharger
2/15 99
Wastegate
2/15 99
Wastegate Control
2/15 99
Wastegate Adjusting Rod
2/15 99
W
Wastegate
Adjustment
2/15 99
Turbocha
arger Shaft Movement
2/15 99
LUBRIC
CATION
SYSTEM
2/15 99
Lu
ubricating Oil System
2/15 99
Oil Pump
2/15 99
Oil Pump Inspection
2/15 99
Oil Pump Inspection
2/15 99
Oil Pressure Relief Valve Location
2/15 99
Relief And Regulating Valves
2/15 99
Relief Valve Aperture
2/15 99
Oil Pressure Regu

ulating Valve Location
2/15 99
Oil Coolerr And Filter Assembly
2/15 99
Oil Cooler Assembly
2/15 99
Oil Cooler
C
Exploded View
2/15 99
10
Oil Cooler Pressure Test
2/15 99
10
O Filter Bypass Valve

Oil
Normal Flow
Restricted Flow
2/15 99
10
Oil Temperature Control Valve
2/15 99
10
Oil Temperature Control
2/15 99
10
Oil Filter / Cooler / Filter

F
Header Oil Flow
2/15 99
10
Oil Spray Tubes
2/15 99
10
Oil Spray
S
Tubes Installed
2/15 99
10
Series 40E
Oil Degradation
Oil Chang
ge Interval
Oxidation
Additive Depletion
Combustion Products
Increased Viscosity,
Hard Starting
Increased Wear and
D
Deposits
it
All of the Above
Oil Degradation is Affectted by Engine Operating

Ti
Time,
Fuel
F l Rate
R t and
d Oil API
A Classification
Cl
ifi ti
2/15 99
10
Series 40E
SAE Viscosity Grades
30
20W-40
15W
W-40 PREFERRED
PREFERRED
10W
W-30
5W-30
0W-30
F
-20
C -30
2/15 99
-10
-25
0
-20
10
-15
-10
20
30
-5
40
0
0
50
60
70
10
15
20
80
25
90
30
100
35
40
10
Series 40E
Oil Change Intervals
19,300
,
km (12,000
( ,
m
miles)
)
450 Hours
6 Months
Oil Capacity
22.7
22 7 L (24 q
quarts)
arts) without
witho t filter change
26.4 L (28 quarts) with
w filter change
2/15 99
Sulfur Content of Fuel
Oil Change Interval
Below 0.5%
0.5% to 1.0%
Above 1.0%
Normal
3/4 Normal
1/2 Normal
11
COOLING
G SYSTEM
FEATU
URES AND BENEFITS
WATER PUMP
BELT DRIVEN (SERPENTINE
E)
THREE RATIOS INDEPENDE
ENT OF FAN SPEED
1:3:1
131
1:5:1
1:8:1
DEPENDENT ON ENGINE HP
RATING AND APPLICATIO
ON
2/15 99
11
COOLANT SYSTEM FLOW
2/15 99
11
WAT
TER PUMP POSITION
2/15 99
11
WATE
ER PUMP ASSEMBLY
2/15 99
11
WATE
ER PUMP - DAMAGED
2/15 99
11
Series 40E
Watter Pump Sub Assembly
Water Pump
Seal Assembly
Water Pump
p
Impeller Assembly
Fan
n And Pulley Hub
Bearing Shaft
2/15 99
Water Pump Housing
11
THE
ERMOSTAT POSITION
2/15 99
11
Series 40E
Thermostat Operation
Out To
R di t
Radiator
O--Ring
In From
Engine
g
In From
Engine
2/15 99
Thermosta
at
In Open
Position
o
Coolant To
Radiator
By-Pass
Closed
By-Pass
B
Pass To
Water Pump
Thermostat
In Closed
Position
By-Pass Open,
Recirculation
To Water Pump
11
COOLANT FILTER
2/15 99
12
Series 40E
Coolantt Filter With Check Valve
Valve Spring
Valve Cage
Check Valve
Assembly
Valve Body
Filter Element
2/15 99
Valve D
Disk
Outlet
Inlet
12
FREE
EZE PROTECTION
REFRACTOMETER
PG & EG
HYDROMETER
EG ONLY
2/15 99
12
FUEL S
SYSTEM
YSTEM
Series 40E
In
njection Control System
2/15 99
12
Series 40E
Fuel System Flow
2/15 99
12
Series 40E
Injection Con
ntrol Pressure Reservoir
2/15 99
12
Series 40E
High Pressure Oil Pump
2/15 99
12
Series 40E
Injectio
on Control System Flow
2/15 99
12
HEUI INJJECTOR
OPERA
ATION
Series 40E
HEUI Fuel Injector
2/15 99
13
Series 40E
H
HEUI
Injector Schematic
Poppet Valve
Intensifier
Piston
Plunger
High Pressure
Oil Channel
Fuel Inlet
2/15 99
13
Series 40E
Fill Cycle
2/15 99
13
Series 40E
Solenoid Energized
2/15 99
13
Series 40E
Injection Delay
2/15 99
13
Series 40E
Main Injection
2/15 99
13
Heui_iny.exe
2/15 99
13
Series 40E
Injector Harness
2/15 99
13
ABBREV
VIATIONS
AND ACR
RONYMS
Series 40E
Abbre
eviations and Acronyms
APS
Accelerator Position
Sensor
ATA
American Trucking
Association
Exhaust
aust Back
ac Pressure
essu e
Sensor
EBPR Exhaust Back Pressure
Regulator
EBP
BARO Barometric Pressure

Sensor
ECM
Electronic Control
Module
BNO
Brake Normally Open

Switch
ECI
Engine Crank Inhibit
CMP
Camshaft Position Sensor
ECT
Engine Coolant
Temperature Sensor
COL
Change Oil Lamp
EOP
Engine Oil Pressure Sensor
DDS
Driveline Disengagement
g g
Switch
EOT
Engine Oil Temperature

Sensor
2/15 99
13
Series 40E
Abbre
eviations and Acronyms
EST
S
Electronic
ect o c Se
Service
ce Tool
oo
IVS
Idle Validation Switch
HEUI
Hydraulically Activated
Electronically Controlled
Unit Injector
MAP
Manifold Absolute Pressure

Sensor
NPS
Neutral Position Switch
OCP
Overcrank Protection
Oil Water Warning Light
HPG
Hydraulic Pressure
Governing
IAT
Intake Air Temperature

Sensor
OWL
ICP
Injection
j
control Pressure
Sensor
SCCS Speed Command Control

Switch
IPR
Injection Pressure Regulator
VREF Voltage Reference
2/15 99
14
ELECTRONIC
ENGINE CONTROL
C
Series 40E
Processing Information
Input
Processing
O
Outputs
2/15 99
14
Series 40E
Consolidated Engine Controller
Electrronic
Control
Mod
dule
(EC
CM)
EEPR
ROM
2/15 99
14
Series 40E
ECM
2/15 99
14
Series 40E
Electrronic
Control
Mod
dule
(EC
CM)
EEPR
ROM
2/15 99
14
Series 40E
Cam Position Sensor
2/15 99
14
Series 40E
Timing Disk
2/15 99
14
Series 40E
Cam Position Sensor
Input
Processing
Outputs
Unit
Injectors
CMP
Sensor
EC
CM
IPR
Tachometer
2/15 99
14
Series 40E
Accelerator
Position Sensor
With Idle Validation
Electrronic
Control
Mod
dule
(EC
CM)
EEPR
ROM
2/15 99
14
Series 40E
Acce
elerator Position Sensor
2/15 99
15
Series 40E
Acce
elerator Position Sensor
Input
put
APS
Proce
ocess
ssing
g
EC
CM
Outputs
Unit
Injectors
IPR
2/15 99
15
Series 40E
Accelerator
Position Sensor
Injection Control Pressure
Electrronic
Control
Mod
dule
(EC
CM)
EEPR
ROM
2/15 99
15
Series 40E
Injection Control
C
Pressure Sensor
2/15 99
15
Series 40E
Injection Control
C
Pressure Sensor
Input
Processing
Outputs
Unit
Injectors
ICP
Sensor
EC
CM
IPR
Engine
Warning
Lamp
2/15 99
15
Series 40E
Accelerator
Position Sensor
Electrronic
Control
Mod
dule
(EC
CM)
EEPR
ROM
2/15 99
15
Series 40E
Manifold Ab
bsolute Pressure Sensor
2/15 99
15
Series 40E
Manifold Ab
bsolute Pressure Sensor
Input
Processing
MAP
Sensor
EC
CM
Output
Unit
Injectors
2/15 99
15
Series 40E
Accelerator
Position Sensor
Barometric Pressure
Electrronic
Control
Mod
dule
(EC
CM)
EEPR
ROM
2/15 99
15
Series 40E
Baro
ometric Pressure Sensor
2/15 99
15
Series 40E
Baro
ometric Pressure Sensor
Input
put
BARO
Sensor
Proce
ocess
ssing
g
EC
CM
Outputs
Unit
Injectors
IPR
2/15 99
16
Series 40E
Accelerator
Position Sensor
Barometric Pressure
Electrronic
Control
Mod
dule
(EC
CM)
Oil Pressure
EEPR
ROM
2/15 99
16
Series 40E
Engine
e Oil Pressure Sensor
2/15 99
16
Series 40E
Eng
gine Oil Pressure Sensor
Input
Processing
Outputs
Unit
Injectors
EOP
Sensor
Engine
Warning
Lamp
EC
CM
Warning
Buzzer
Oil / Water
Lamp
Oil Pressure
Gauge
2/15 99
16
Series 40E
Accelerator
Position Sensor
Barometric Pressure
Electrronic
Control
Mod
dule
(EC
CM)
Oil Pressure
Oil / Coolant Temperature
EEPR
ROM
2/15 99
16
Series 40E
Engine Oil Temperature Sensor
2/15 99
16
Series 40E
Engine Oil Temperature Sensor
Input
Processing
Outputs
Unit
Injectors
EOT
Sensor
EC
CM
IPR
Oil
Temperature
Gauge
2/15 99
16
Series 40E
Engine Coola
ant Temperature Sensor
2/15 99
16
Series 40E
Engine Coola
ant Temperature Sensor
Input
Processing
Outputs
Unit
Injectors
ECT
Sensor
Engine
Warning
Lamp
EC
CM
Warning
Buzzer
Oil / Water
Lamp
2/15 99
Water
Temperature
Gauge
16
Series 40E
Accelerator
Position Sensor
Barometric Pressure
Electrronic
Control
Mod
dule
(EC
CM)
Oil Pressure
EEPR
ROM
Air Temperature Sensor
2/15 99
16
Series 40E
Intake Air
A Temperature Sensor
2/15 99
17
Series 40E
Intake Airr Temperature Sensor
Input
put
IAT
Proce
ocess
ssing
g
EC
CM
Outputs
Unit
Injectors
IPR
2/15 99
17
Series 40E
Accelerator
Position Sensor
Barometric Pressure
Electrronic
Control
Mod
dule
(EC
CM)
Oil Pressure
EEPR
ROM
Coolant Level
2/15 99
17
Series 40E
Coolant Level Sensor
2/15 99
17
Series 40E
Grounding / Voltage
V
Divider Switches
2/15 99
17
Series 40E
Accelerator
Position Sensor
Barometric Pressure
Electrronic
Control
Mod
dule
(EC
CM)
Oil Pressure
EEPR
ROM
Coolant Level
VSG Control
2/15 99
17
Series 40E
Variable Speed Go
overnor Throttle Control
2/15 99
17
Series 40E
Circuits 545 & 541
Bulkhead
Connector
Resume / Increase
Speed
5
545
10/K
VIH-to-ECM
Connector
545
31
544
5
541
11/L
541
32
Set / Decrease
Speed
2/15 99
17
Series 40E
Accelerator
Position Sensor
Barometric Pressure
Electrronic
Control
Mod
dule
(EC
CM)
Oil Pressure
EEPR
ROM
Coolant Level
VSG Control
Hydraulic Pressure Governor

2/15 99
17
Series 40E
Hydraulic Pressure
e Governing Application
2/15 99
17
Series 40E
Hydraulic Pres
ssure Governing Sensor
Input
Processing
HPG
EC
CM
Output
Unit
Injectors
2/15 99
18
Series 40E
Accelerator
Position Sensor
Barometric Pressure
Electrronic
Control
Mod
dule
(EC
CM)
Oil Pressure
EEPR
ROM
Coolant Level
VSG Control

2/15 99
Diagnostic
Request
Self Test
Input
18
Series 40E
S Test Input Switch
Self
2/15 99
18
Series 40E
Accelerator
Position Sensor
Barometric Pressure
Electrronic
Control
Mod
dule
(EC
CM)
Oil Pressure
EEPR
ROM
Coolant Level
VSG Control

2/15 99
Diagnostic
Request
+
B tt
Battery
Self Test
Input
18
Series 40E
Power Supply and Return System
2/15 99
18
Series 40E
Accelerator
Position Sensor
Barometric Pressure
Electrronic
Control
Mod
dule
(EC
CM)
Oil Pressure
EEPR
ROM
Coolant Level
VSG Control

2/15 99
Diagnostic
Request
+
B tt
Battery
Cruise/PTO Control
Vehicle Speed Limiting
Vehicle Speed Sensor
Self Test
Input
18
Series 40E
2/15 99
18
Series 40E
Input
put
VSS
Proce
ocess
ssing
g
Outputs
Gauges
EC
CM
Unit
Injectors
2/15 99
18
Series 40E
Accelerator
Position Sensor
Barometric Pressure
Electrronic
Control
Mod
dule
(EC
CM)
Oil Pressure
EEPR
ROM
Coolant Level
Check
Engine
VSG Control

2/15 99
Diagnostic
Request
+
B tt
Battery
Cruise/PTO Control
Self Test
Input
18
Series 40E
Check Engine Lamp
2/15 99
18
Series 40E
Accelerator
Position Sensor
Barometric Pressure
Electrronic
Control
Mod
dule
(EC
CM)
Oil Pressure
EEPR
ROM
Stop
p
Engine
Coolant Level
Check
Engine
VSG Control

2/15 99
Diagnostic
Request
+
B tt
Battery
Cruise/PTO Control
Self Test
Input
19
Series 40E
Stop Engine Lamp
2/15 99
19
Series 40E
Accelerator
Position Sensor
Barometric Pressure
Electrronic
Control
Mod
dule
(EC
CM)
Oil Pressure
EEPR
ROM
Service
Engine
Stop
p
Engine
Coolant Level
Check
Engine
VSG Control

2/15 99
Diagnostic
Request
+
B tt
Battery
Cruise/PTO Control
Self Test
Input
19
Series 40E
Service Engine Lamp
2/15 99
19
Series 40E
Accelerator
Position Sensor
Barometric Pressure
Electrronic
Control
Mod
dule
(EC
CM)
Oil Pressure
Injection
ject o Pressure
essu e Regulator
egu ato
EEPR
ROM
Service
Engine
Stop
p
Engine
Coolant Level
Check
Engine
VSG Control

2/15 99
Diagnostic
Request
+
B tt
Battery
Cruise/PTO Control
Self Test
Input
19
Series 40E
Injec
ction Pressure Regulator
2/15 99
19
Series 40E
Injec
ction Pressure Regulator
Inputs
Processing
Output
ICP
Sensor
EOT
Sensor
CMP
Sensor
EC
CM
IPR
APS / IVS
MAP
BARO
2/15 99
IAT
19
Series 40E
Accelerator
Position Sensor
Barometric Pressure
Electrronic
Control
Mod
dule
(EC
CM)
Oil Pressure
EST Interface
Injection
ject o Pressure
essu e Regulator
egu ato
EEPR
ROM
Service
Engine
Stop
p
Engine
Coolant Level
Check
Engine
VSG Control

2/15 99
Diagnostic
Request
+
B tt
Battery
Cruise/PTO Control
Self Test
Input
19
Series 40E
EST Interface
2/15 99
19
Series 40E
Accelerator
Position Sensor
Barometric Pressure
Electrronic
Control
Mod
dule
(EC
CM)
Communication, Engine Data Line
Oil Pressure
EST Interface
Injection
ject o Pressure
essu e Regulator
egu ato
EEPR
ROM
Service
Engine
Stop
p
Engine
Coolant Level
Check
Engine
VSG Control

2/15 99
Diagnostic
Request
+
B tt
Battery
Cruise/PTO Control
Self Test
Input
19
Series 40E
Engine Data Line
Engine
Control Module
Vehicle Components
C t l Module
Control
M d l
2/15 99
20
Series 40E
Accelerator
Position Sensor
Barometric Pressure
Electrronic
Control
Mod
dule
(EC
CM)
Oil Pressure
Engine Crank Inhibit Relay

EST Interface
Injection
ject o Pressure
essu e Regulator
egu ato
EEPR
ROM
Service
Engine
Stop
p
Engine
Coolant Level
Check
Engine
VSG Control

2/15 99
Diagnostic
Request
+
B tt
Battery
Cruise/PTO Control
Self Test
Input
20
Series 40E
Engine Crrank Inhibit Relay Circuit
Ignition
Switch
DDS
85
30
Engine Crank
Inhibit Relay
86
87A
87
Start
Relay
ECM
2/15 99
20
Series 40E
Accelerator
Position Sensor
Barometric Pressure
Electrronic
Control
Mod
dule
(EC
CM)
Oil Pressure
(VRE) Vehicle Retarder

EST Interface
Injection
ject o Pressure
essu e Regulator
egu ato
EEPR
ROM
Service
Engine
Stop
p
Engine
Coolant Level
Check
Engine
VSG Control

2/15 99
Diagnostic
Request
+
B tt
Battery
Cruise/PTO Control
Self Test
Input
20
Series 40E
Vehicle Retarder
Engine
Control Module
Vehicle Retarder
R l or Solenoid
Relay
S l
id
2/15 99
20
Series 40E
Accelerator
Position Sensor
Barometric Pressure
Electrronic
Control
Mod
dule
(EC
CM)
Oil Pressure
Fan Controls

EST Interface
Injection
ject o Pressure
essu e Regulator
egu ato
EEPR
ROM
Service
Engine
Stop
p
Engine
Coolant Level
Check
Engine
VSG Control

2/15 99
Diagnostic
Request
+
B tt
Battery
Cruise/PTO Control
Self Test
Input
20
Series 40E
Fan / Shutter Control
Engine
Control Module
Vehicle Fan / Shutter

R l or Solenoid
Relay
S l
id
2/15 99
20
Series 40E
Accelerator
Position Sensor
Barometric Pressure
Electrronic
Control
Mod
dule
(EC
CM)
Oil Pressure
HEUI
Fan Controls

EST Interface
Injection
ject o Pressure
essu e Regulator
egu ato
EEPR
ROM
Service
Engine
Stop
p
Engine
Coolant Level
Check
Engine
VSG Control

2/15 99
Diagnostic
Request
+
B tt
Battery
Cruise/PTO Control
Self Test
Input
20
Series 40E
E
ECM
Control Of Injectors
EOP
CMP
ECM
IPR
ECT
T
ICP
EOT
Injectors
ECT
ECM
IPR
ICP
MAP
EOT
EOP
CMP
Engine
g
Coolant
Temperature Sensor
Electronic Control Module
Injection Pressure
Regulator
S
Sensor
Engine Oil Temperature
Sensor
Engine Oil Pressure
Press re Sensor
MAP
2/15 99
20
Series 40E
Accelerator
Position Sensor
Barometric Pressure
Electrronic
Control
Mod
dule
(EC
CM)
Oil Pressure
HEUI
Fan Controls

EST Interface
Injection
ject o Pressure
essu e Regulator
egu ato
EEPR
ROM
Service
Engine
Stop
p
Engine
Coolant Level
Check
Engine
VSG Control

2/15 99
Diagnostic
Request
+
B tt
Battery
Cruise/PTO Control
Self Test
Input
20
WIR
RING
FEATU
URES
Series 40E
Wiring Features
The electronic controll system
y
requires
q
different voltage value
es to operate.
5 volts
Sensor inputs
12 / 24 volts
Vehicle charging syste
em
100+ volts
Injector solenoid opera
ation
2/15 99
21
Series 40E
Wirre Length Requirements
Covered Circuit Length
Maximum Deviation
0 to 49 mm
5.0 mm
50 to 151 mm
7.5 mm
152 to 304 mm
12 5 mm
12.5
305 to 609 mm
15.0 mm
610 to 914 mm
17.5 mm
915 to 1219 mm
20.0 mm
1220 to 1224 mm
22.5 mm
1225 to 1829 mm
25.0 mm
1830 and g
greater
25 + .25 mm for every 300 mm

2
i
increment
greater than 1830 mm
2/15 99
21
Series 40E
Condu
uit Diameter for 18 AWG
Quantity of Wires to be Covered Recommended Conduit Diameter
Up to 3
6 mm
4 to 5
9 mm
6 to 7
10 mm
8 to 10
13 mm
11 to 17
16 mm
18 to 21
19 mm
22 to 28
22 mm
27 to 37
25 mm
38 to 40
30 mm
2/15 99
21
Series 40E
Terminal Load Criteria
Wire Gauge
Must Withstand Applied Load
14 AWG
222 N
16 AWG
133 N
18 AWG
89 N
2/15 99
21
Series 40E
Engine Harness
EOP
CM
MP
ECM
IPR
E
ECT
Sensor Input To The

ECM
Drive Injector
Solenoids
ICP
EOT
Injectors
MAP
2/15 99
21
Series 40E
Vehicle Interface Harness
OEM Supplied
Power ECM
Sensor Input To The
ECM
Auxiliary Systems
Communication To The
ECM
ECM Outputs
2/15 99
21
WIRE CR
RIMPING
EXER
RCISE
Series 40E
Termina
al Installation Technique
Part Number
Description
n
Installation
Technique
Refer to
Section
1689464C1
ATS Connector Terminal

T
3.7.4.1
2003343C1
BAPS Connector Terminal

T
3.7.4.2
Packard 12020156
Main Power Relay Terminal
3.7.4.1
2041419C1
VIH-to-ECM Connecttor Terminal
3.7.4.3
VIH-to-ECM Connector Terminal
3.7.4.3
Main Power Relay Terminal
3.7.4.1
12103881
HPS Connector T
Terminal
3742
3.7.4.2
235135053
J1708 / J1587 Data Link

L
Terminal
3.7.4.4
3 11 3 1
3.11.3.1
2041420C1
Packard 12066614
23516830
23515462
2/15 99
M i VIH Connecto
Main
C
tor Terminal
T
i l
21
Series 40E
Push To Seat Terminal
Terminal
Connector Assembly
Terminal Lock
2/15 99
21
Series 40E
Seal Positioning Push To Seat Terminals
2/15 99
22
Series 40E
Push To Seat Terminals
Contact
Cable Core Wings
Insulation Wings
Seal
2/15 99
22
Series 40E
Push To Seat Terminals
Cable
Terminal
Seal
2/15 99
22
Series 40E
Pull To Seat Terminal
Seal
Pull-To-Seat
Connector
2/15 99
22
Series 40E
Pull To Seat Terminal
J 38706
Or Equiv
valent
Cable
Terminal
2/15 99
22
Series 40E
Crimp Tool
T
for Augat Terminals
2/15 99
22
Series 40E
Pull-to-Seat Terminal Method C
18 ga GXL Wire
16 ga GXL Wire
Terminal (14 and 16 ga Wire),
P/N: 2041420C1
14 ga GXL Wire
Terminal (18 ga Wire),
P/N: 2041419C1
2/15 99
22
Series 40E
Guidelines for Acc
ceptable Terminal Crimp
Crim
mp Height
Crimp Width
14 AWG Insulation
3.2
22 mm
3.48 mm
14 AWG Conductor
1.5
50 mm
2.44 mm
16 AWG Insulation
2.9
90 mm
3.48 mm
16 AWG Conductor
1.3
34 mm
2.44 mm
18 AWG Insulation
25
2.5
59 mm
2 84 mm
2.84
18 AWG Conductor
1.2
24 mm
2.05 mm
60-pin Terminal Detail
2/15 99
22
Series 40E
Deutsch Terminal Positioning
0.8 mm
6.0 mm
2/15 99
22
Series 40E
Deuts
sch Terminal Installation
25.4 mm
2/15 99
22
Series 40E
Deutsch Terminal
Unlocked Position
Locked Position
2/15 99
23
Series 40E
Deutsch Removal Tool
2/15 99
23
Series 40E
Cannon Connector Crimp Tool
Latch
Crimp Tool
Locator
Latch
Locator
Locator
Color
Code
Turret
Index
Mark
Lock Pin
2/15 99
Dial
23
Series 40E
Cannon Connector
2/15 99
23
Series 40E
Cannon Connector Ex
xploded View (Plug End)
2/15 99
23
Series 40E
Cannon Exploded View (Socket End)
2/15 99
23
Series 40E
Cannon Terminal Insertion
Insertion
T l
Tool
Guide Pin
Shoulder
2/15 99
23
Series 40E
Cannon Connector
C
Removal Tool
Socket
Extraction End
Handle
Lock Ring
Pin Extraction End

2/15 99
23
WIRE SP
PLICING
GUIDE
ELINES
Series 40E
Splicing Tools
Tool
Part Number
Heat Gun
----
Sn 60 solder with rosin core flux
----
Wire Stripper
Kent-Moore J 35615 or equivalent
Splice Clips
DDC P/N 0597428 or equivalent
Heat Shrink Tubing
Refer to Section 3.7.7.5
2/15 99
23
Series 40E
Splicing Straight Leads
Clip
2/15 99
24
Series 40E
Recommended Splic
cing Tools Alt. Method 1
T l
Tool
Heat Gun
Wire Stripper
P t Number
Part
N
b
---Kent-Moore J-35615 or equivalent
Splice Clips
23519359 or equivalent
Heat Shrink Tubing
Terminal Crimper for 16 and 18 AWG
Kent-Moore J-38125-6

Terminal Crimper for 10 AWG
2/15 99
24
Series 40E
Splicing Straiight Leads Alt. Method 1
2/15 99
24
Series 40E
Recommended Splic
cing Tools Alt. Method 2
T l
Tool
Heat Gun
Wire Stripper
P t Number
Part
N
b
---Kent-Moore J-35615 or equivalent
Splice Clips
0597428 or equivalent
Heat Shrink Tubing
Kent-Moore J-38125-6

Terminal Crimper for 10 AWG
2/15 99
24
Series 40E
Splicing Straight Leads Alt. Method 2
Splice Clip, P/N 597428
or Equivalent
Shrink Tubing
6mm (.25)) Min.

Both En
nds
2/15 99
24
Series 40E
Strain Relief of Spliced Joint
Apply Two
L
Layers
off Tape
T
45 mm
Minimum
Both Ends
Generic
c
Insulate
ed
Splice Arrea
25 mm
Minimum
Both Ends
2/15 99
24
Series 40E
S
Staggering
Wire Splices
65 mm Minimum
Between Splices
2/15 99
C
Correct
Method
Tape Spliced
Wires Together
Incorrect Method
24
Series 40E
Shrink Wrap
The Heat Shrink Wrap mu
ust overlap the wire
insulation by about 6mm on both sides of the splice
2/15 99
24
DIGIITAL
MULTIM
METER
Series 40E
Digital Multimeter
Analog Multimeters are not
suiitable for diagnostic work
on Navistar electronics
2/15 99
24
Series 40E
Diigital Multimeter Display
Touch Hold
Manual Range
Measurement
Units
Replace
Battery
Range Indicator
Zero Function
2/15 99
25
Series 40E
DVOM Pushbuttons
Zero Function
Manual / Auto
Range Select
Smooth / Backlight
2/15 99
25
Series 40E
Current Measurement
2/15 99
25
Series 40E
Voltage Measurement
2/15 99
25
Series 40E
R
Resistance
Measurement
2/15 99
25
ELECTRONIC
SERVICE TOOL
Series 40E
Electronic Service Tool
2/15 99
25
Series 40E
Elec
ctronic Service Tool Map
2/15 99
25
ENG
GINE
DIAGNO
OSTICS
HARD START
T / NO START
Series 40E
D
Diagnostics
Preparation
2/15 99
25
Series 40E
D
Diagnostics
Preparation
2/15 99
26
Series 40E
D-200 Test Kit
2/15 99
26
Series 40E
Fuel Quality
1. Sufficient Clean
n Fuel
Free off Water-Icing

F
W t I i and
d clouding
l di
Correct grade of fuel
Method
Check
Visual
2/15 99
26
Series 40E
Visual Inspection
2. Visual Inspectio
on
Inspect for leaks

Inspect for loose conne
ections, etc.
Fuel
Oil
Method
Coolant
Electrical
Air
Check
Visual
2/15 99
26
Series 40E
Engine Oil Level
3. CHECK ENGINE
E OIL LEVEL
Check engine crankcas

se oil level
Check for contaminants
s (fuel, coolant)
Correct Grade / Viscosiity
Miles / Hours on oil
Check oil pressure on dash
d
gauge
Method
Check
Visual
2/15 99
26
Series 40E
Inta
ake / Exhaust Restriction
4. Intake / Exhaustt Restriction
Inspect
p
hoses and pipi
p p ng
g
Check filter minder
Inspect exhaust system
m
Method
Check
Visual
2/15 99
26
Series 40E
Inlet Restriction Gauge
2/15 99
26
Series 40E
EST Tool Fault Codes
5. EST TOOL - FAU
ULT CODES
I t ll Electronic
Install
El t
i Servic
S
ice Tool
T l
Active
Inactive
See Electronic Diagnos
stic Form for codes
2/15 99
26
Series 40E
Engine Off Tests
6a. EST - ENGINE OFF TESTS
Select
S
l t Standard
St d d Test
T t fr
from the
th Engine
E i Off Test
T t
Menu
Faults
Found
Repair fault codes befo

ore continuing
2/15 99
26
Series 40E
Injector Buzz Test
6b. EST - INJECTO
OR BUZZ TEST
NOTE: Standard Test mus
st be performed first, in
order to gain acces
ss to the Injector Buzz
Test.
Select Injector Test from
m the Engine Off Test
Menu
Faults
F
Found
d
stic Form for codes
2/15 99
26
Series 40E
Flash Codes
7. STI BUTTON - FLASH CODES
NOTE: Perform this test iff a EST is not available or
is inoperative
Depress and hold Eng

gine Diagnostics switch,
then turn the ignition sw
witch to the ON
position.
Faults
Found
2/15 99
agnostic
g
form if fault
Refer to Electronic Dia
code(s) are set
27
Series 40E
S Test Input Switch
Self
2/15 99
27
Series 40E
EST - Data List
8. EST TOOL - DATA
A LIST
2/15 99
Select and enter the follow

wing data as the first 3 lines
in a custom data list.
Monitor the data while cra
anking the engine for 20
seconds
d minimum
i i
Data
Sp
pec
Bat voltage
7 volts
lts min.
i
Eng. RPM
130 RPM
M min.
ICP pressure
500 PS
SI min.
min
Actual
If voltage is low, refer to ECM

E
diagnostics
If no RPM is noted rechec
ck fault codes
If ICP pressure is low, refe
er to Test 10
27
Series 40E
ECM Voltage
9a. ECM VOLTAGE
E
is inoperative
Check while cranking the engine

Measure with DVOM at three locations with breakout
box connected at chassis
s harness connector on ECM
Pins: (21+ & 1-) (22+ & 2-) (2
24+ & 23-)
2/15 99
Instrument
Spec
c
DVOM &
Breakout box
7 vollts
minim
mum
Actual
If voltage is low, refer to

t ECM diagnostics
27
Series 40E
ECM Voltage
2/15 99
27
Series 40E
Engine Cranking RPM
9b. ENGINE CRAN
NKING RPM
Minimum 130 RPM eng

gine cranking speed for 20
seconds
d
Measure with breakoutt box engine harness on
ECM @ pins 51+ & 19Instrument
Spe
ec
DVOM
51+ & 19-
H
26 Hz
mum
Minim
Actual
If no frequency,
q
y, recheck fault codes
2/15 99
27
Series 40E
Engine Cranking RPM
2/15 99
27
Series 40E
9c. Injection Contrrol Pressure
Minimum 130 RPM cra

ank speed for 20 seconds
Measure with breakoutt box connected to Engine
Harness on ECM @ pin
ns 16+ & 19- or breakout
tee signal (green) & ground (black)
Instrument
Spe
ec
DVOM
16+ & 19-
olt
1 vo
mum
Minim
Actual
If ICP pressure is low, refer

r
to Test 10
2/15 99
27
Series 40E
2/15 99
27
Series 40E
J-43103
2/15 99
27
Series 40E
Low ICP Pressure Test
10. LOW ICP PRESS
SURE TEST
2/15 99
Remove EOT sensor and check for oil in reservoir and

reinstall EOT
Remove high pressure ho
ose from oil manifold
Attach adapter and ICP se
ensor to the hose
Monitor pressure while crranking engine
Instrument
Spec
EST
500 PSI min.

m
DVOM
1 volt min.
Actual
If pressure is within speciifications check for high

pressure oil leak
if pressure is still low veriify that the pump is rotating
If pressure is still low repllace IPR and retest
28
Series 40E
Oil Reservoir Check
2/15 99
28
Series 40E
Fuel Pump Pressure (Cranking)
11. Fuel Pump Pre
essure
2/15 99
Measure at bleeder vallve on filter head

Minimum 130 RPM cra
ank speed for 20 seconds
Instrument
Spe
ec
0 - 160 PSI
Gauge
P
20 PSI
minim
mum
Actual
If pressure is low, repllace fuel filter, clean fuel

strainer and retest
If pressure is still low,
low, perform Transfer Pump
Restriction Test 2b (off Performance Diagnostics)
28
Series 40E
Fuel Pump Pressure (Cranking)
2/15 99
28
ENG
GINE
DIAGNO
OSTICS
PERFORMANCE
E DIAGNOSTICS
Series 40E
D
Diagnostics
Preparation
2/15 99
28
Series 40E
D-200 Test Kit
2/15 99
28
Series 40E
Engine Oil Level
1. CHECK ENGINE
E OIL LEVEL
Check engine crankcas

se oil level
Check for contaminants
s (fuel, coolant)
Correct Grade / Viscosiity
Method
Check
Visual
2/15 99
28
Series 40E
S
Sufficient
Fuel / Pressure
2 SUFFICIENT FUEL / PRESSURE
2.
2/15 99
Drain sample from tank

k(s)
Inspect fuel for contam
mination
Measure fuel pressure at fuel filter bleeder
Measure pressure at high idle
I t
Instrument
t
S ec
Spe
0 - 160 PSI
Gauge
30 PSI
P
minim
mum
@ High
h idle
A t l
Actual
If pressure is low replac

ce fuel filter, clean fuel
strainer and retest
If pressure is still low, proceed
p
with step 2b
28
Series 40E
Tra
ansfer Pump Restriction
2b. TRANSFER PUM
MP RESTRICTION
Measure at fuel filter inlett @ High idle
Instrument
0 - 30 Hg
Vacuum gauge
S ec
Spe
Actual
Less than
8 Hg
8
H
If restriction is high
high, check for blockage between pump
and fuel tank.
efer to Diagnostic Manual 11-10
If restriction is < 8 Hg., re
2/15 99
28
Series 40E
Tra
ansfer Pump Restriction
2/15 99
29
Series 40E
EST Tool Fault Codes
3. EST TOOL - FAU
ULT CODES
I t ll Electronic
Install
El t
i Servic
S
ice Tool
T l
Active
Inactive
stic Form for codes
2/15 99
29
Series 40E
Engine Off Tests
4a. EST - ENGINE OFF TESTS
Select
S
l t Standard
St d d Test
T t fr
from the
th Engine
E i Off Test
T t
Menu
Faults
Found
Repair fault codes, befo

ore continuing
2/15 99
29
Series 40E
Injector Buzz Test
4b. EST - INJECTO
OR BUZZ TEST
order to gain acces
ss to the Injector Buzz
Test.
m the Engine Off Test
Menu
Faults
F
Found
d
stic Form for codes
2/15 99
29
Series 40E
Flash Codes
5. STI BUTTON - FLASH CODES
is inoperative
Depress and hold Eng

gine Diagnostics switch,
then turn the ignition sw
witch to the ON
position.
Faults
Found
2/15 99
agnostic
g
form if fault
code(s) are set
29
Series 40E
S Test Input Switch
Self
2/15 99
29
Series 40E
Intake Restriction
6. INTAKE RESTRIICTION
Measure at High
g idle an
nd no load
Use manometer or mag
gnehelic
Instrument
Manometer or
Magnehelic
Sp
pec
Actual
12.5
H2O
2/15 99
29
Series 40E
Engine Running Test
7a. EST - ENGINE RUNNING TEST
Select
S
l t Standard
St d d Test
T t fr
from the
th Engine
E i Running
R
i
Test Menu
Faults
Found

agnostic form if fault
code(s) are set
2/15 99
29
Series 40E
Injector Testt (Cylinder Contribution)
7b. EST TOOL - INJECTOR TEST
order to gain acces
ss to the Injector Test
Test.

m the Engine Running
Menu
Faults
F
Found
d
2/15 99

agnostic
g
form if fault
code(s) are set
29
Series 40E
Fuel Pressure Full Load
8. FUEL PRESSUR
RE (FULL LOAD)
Measure fuel pressure at fuel filter bleeder

Measure pressure at fu
ull load rated speed
Instrument
Spe
ec
0 - 160 PSI
Gauge
P
30 PSI
minim
mum
Actual
If pressure is low repla

ace fuel filter, clean fuel
strainer and retest
If pressure is still low perform test 2B
2/15 99
29
Series 40E
Fuel Pump Pressure Full Load
2/15 99
30
Series 40E
9. ICP PRESSURE
2/15 99
Monitor ICP pressure and

d engine RPM with the EST
tool in data list mode. Or use breakout tee and DVOM
Data
Spec
Low Idle
v
PSI / volts
High Idle
v
PSI / volts
Full Load
PSI / volts
v
Actual
If pressure is low or unsta

able disconnect ICP sensor
and retest
problem is resolved,, reffer to ICP diagnosis
g
If p
If pressure is still low or unstable,
u
replace IPR and
retest
30
Series 40E
J-43103
2/15 99
30
Series 40E
Boost Pressure
10. BOOST PRESS
SURE
Monitor boost pressurre and engine RPM with the

EST tool
t l in
i data
d t list
li t mo
ode.
d
Or use dash tach and 0 - 30 PSI gauge and T if
EST tool is not availab
ble
Measure at full load rated speed
Spec
Actual
PSI @ RPM
2/15 99
30
Series 40E
Boost Pressure
2/15 99
30
Series 40E
Crankcase Pressure
11. CRANKCASE PRESSURE
P
Measure at road draft tube with orifice tool

J-39267
Measure at High Idle no
o load RPM
Instrument
Spe
ec
0 - 60 H20
Magnehelic
Gauge
< 8
8
H20
Actual
2/15 99
30
Series 40E
Crankcase Pressure
2/15 99
30
Series 40E
Performance Diagnostics
STOP
If guideline data was ob
btained during the first 11
tests, engine operation is satisfactory. No further
testing is required
2/15 99
30
Series 40E
Wastegate Actuator
12. WASTEGATE ACTUATOR
A
Apply regulated supply

y to actuator
Inspect for leakage
Inspect movement
Instrument
Spe
ec
0 - 60
60 PSI
Gauge
28 2 PSI
Actual
2/15 99
30
Series 40E
Wastegate Actuator
2/15 99
30
Series 40E
Exhaust Restriction
13. EXHAUST RES
STRICTION
Visually inspect exhau

ust system for damage
Measure at a point 3 to
o 6 inches after turbo
outlet
Measure at full load & rated speed
Instrument
Spe
ec
Magnehelic
0 - 60 H20
< 33
33 H20
Actual
2/15 99
31
Series 40E
Exhaust Restriction
2/15 99
31
Series 40E
Valve Clearance
14. VALVE CLEARA
ANCE
Engine off: Hot or Cold
Instrument
Spe
ec
Actual
Feeler gauge
2/15 99
31
Series 40E
Valve Adjustment
Adjust
j
Valves
Crankshaft Position
#1 Piston at TDC Compression
#6 Piston at TDC Compression
INT EXH INT

1
3
2
EXH
10
EXH INT
6
7
EXH INT
5
4
EXH INT
8
9
INT EXH
12
11
Front
2/15 99
31

S40e MASTER

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

S40e MASTER

Uploaded by

Copyright:

Available Formats

INTRODUCTION

Starting Engine Serial Nu

Stamped on pad located on crankcase left side

High Pressure Oil

Test valve rotator

Piston Ring Formation

Piston Gage Pins

Piston Piin Bushing Clearance

Liner Protrusion Check

Main Bearing Shells

Rear Seal Wearr Sleeve Replacement

Install Rear Oil Seal

Oil Gallery End Plug

Front Damper Pulley

Electric Heat Pad T

THE AIR SYSTEM

Charge Air Cooler

Wastegate Adjusting Rod

Oil Pump Inspection

Oil Pump Inspection

Oil Pressure Relief Valve Location

Relief And Regulating Valves

Relief Valve Aperture

Oil Pressure Regu

Oil Coolerr And Filter Assembly

Oil Cooler Assembly

Oil Cooler Pressure Test

O Filter Bypass Valve

Oil Temperature Control Valve

Oil Temperature Control

Oil Filter / Cooler / Filter

Oil Spray Tubes

Oil Degradation is Affectted by Engine Operating

Sulfur Content of Fuel

Oil Change Interval

COOLANT SYSTEM FLOW

Water Pump Housing

BARO Barometric Pressure

Brake Normally Open

Engine Crank Inhibit

Camshaft Position Sensor

Change Oil Lamp

Engine Oil Pressure Sensor

Engine Oil Temperature

Idle Validation Switch

Manifold Absolute Pressure

Neutral Position Switch

Intake Air Temperature

SCCS Speed Command Control

Injection Pressure Regulator

VREF Voltage Reference

Hydraulic Pressure Governor

Hydraulic Pressure Governor

Hydraulic Pressure Governor

Hydraulic Pressure Governor

Hydraulic Pressure Governor

Hydraulic Pressure Governor

Air Temperature Sensor

Hydraulic Pressure Governor

Air Temperature Sensor

Hydraulic Pressure Governor

Oil / Coolant Temperature

Air Temperature Sensor