Detroit Diesel

INTRODUCTION
Series 40E
Overhaul / Electronics and Diagnostics

Course
Series 40E
Left Side View
Series 40E25ST0041/2
2/15 99
3
Series 40E
Right Side View
2/15 99
4
Series 40E
Front View
2/15 99
5
Series 40E
Rear View
2/15 99
6
Series 40E
Engine Cutaway
2/15 99
7
Series 40E
Emission Identification
2/15 99
8
Series 40E
Serial Number Description
Engine Identifying Code:
WN1234 N XXXXXXX
WL == 7.6TA
WN == 8.7TA
Country of Origin:
U.S.A.
Starting Engine Serial Number:

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

2/15 99
9
THE FOUR STROKE
CYCLE
FOUR STROKE CYCLE
2/15 99
11
INDUCTION,COMPRESSION,
POWER,EXHAUST.
2/15 99
12
GENERAL
CONSTRUCTION
Series 40E
Cylinder Head Overview
2/15 99
14
Series 40E
Intake Port Protection
2/15 99
15
Series 40E
Cylinder Head Assembly
Fuel Supply High Pressure Oil
2/15 99
16
Series 40E
Injector Sleeve Location
2/15 99
17
Series 40E
Injector Sleeve Tools
2/15 99
18
Series 40E
Injector Sleeve Replacement
2/15 99
19
Series 40E
Supply Manifold
2/15 99
20
Series 40E
Supply Manifold Gasket
2/15 99
21
Series 40E
Cylinder Head Dye Penetrant Crack Check
2/15 99
22
Series 40E
Flatness Check
2/15 99
23
Series 40E
Cylinder Head Thickness Check
2/15 99
24
Series 40E
Valve Guide Removal
2/15 99
25
Series 40E
Valve Guide Installation
2/15 99
26
Series 40E
Valve Seat Removal (Stage 1)
2/15 99
27
Series 40E
Valve Seat Removal (Stage 2)
2/15 99
28
Series 40E
Valve Seat Installation
2/15 99
29
Series 40E
Valve Assembly
2/15 99
30
Test valve rotator
2/15 99
31
Series 40E
Valve Stem Seals
2/15 99
32
Series 40E
Valve Components
2/15 99
33
Series 40E
Valve Depth Check
2/15 99
34
Series 40E
Cylinder Head Overview
2/15 99
35
Series 40E
Rocker Arm Clearance
2/15 99
36
Rocker Lever Bushing Measurement
2/15 99
37
Series 40E
Valve Rotator
2/15 99
38
Valve Assembly Installed
2/15 99
39
Piston 7.6 Liter Engine
2/15 99
40
Piston/Connecting Rod Assembly 7.6L Engine
2/15 99
41
Piston Crown with Skirt and Pin
2/15 99
42
PISTON ASSEMBLY- 8.7 LITER ENGINE
2/15 99
43
Piston Ring Formation
2/15 99
44
Piston Gage Pins
2/15 99
45
Piston Pin Bushing Clearance
2/15 99
46
Cylinder Block
2/15 99
47
Cylinder Liners
2/15 99
48
Series 40E
Cylinder Liner Bore Measurement
2/15 99
49
Crankcase Counterbore Depth
2/15 99
50
Series 40E
Liner Flange Bore Depth
2/15 99
51
Counterboring Tool
2/15 99
52
Lubricate O Rings
2/15 99
53
Liner Protrusion Check
2/15 99
54
Crankshaft
2/15 99
55
Crankshaft Journal
2/15 99
56
Main Bearing Shells
2/15 99
57
Measure Crankshaft Journals
2/15 99
58
Series 40E
Crankshaft Gear Removal
2/15 99
59
Rear Seal Wear Sleeve Replacement
2/15 99
60
Install Rear Oil Seal
2/15 99
61
Rear Oil Seal Installer Tool
2/15 99
62
Rear Oil Seal Alignment
2/15 99
63
Flywheel Installation
2/15 99
64
Camshaft
2/15 99
65
Measure Camshaft Lobe
2/15 99
66
Camshaft Bushing Tool
2/15 99
67
Camshaft Bushing Positions
2/15 99
68
Camshaft Rear O Ring Seal
2/15 99
69
Roller Tappets
2/15 99
70
Oil Gallery End Plug
2/15 99
71
Series 40E
Timing Gear Assembly
2/15 99
72
Series 40E
Crankcase Front Cover (Front Half)
2/15 99
73
Front Damper Pulley
2/15 99
74
Electric Heat Pad To Install Front Pulley
2/15 99
75
THE AIR SYSTEM
Features And Benefits
2/15 99
77
Series 40E
Combustion Air Flow
2/15 99
78
Charge Air Cooler
2/15 99
79
Series 40E
Intake Manifold / Rocker Cover
2/15 99
80
Exhaust Manifold
2/15 99
81
Wastegated Turbocharger
2/15 99
82
Wastegate
2/15 99
83
Wastegate Control
2/15 99
84
Wastegate Adjusting Rod
2/15 99
85
Wastegate Adjustment
2/15 99
86
Turbocharger Shaft Movement
2/15 99
87
LUBRICATION
SYSTEM
2/15 99
89
Lubricating Oil System
2/15 99
90
Oil Pump
2/15 99
91
Oil Pump Inspection
2/15 99
92
Oil Pump Inspection
2/15 99
93
Oil Pressure Relief Valve Location
2/15 99
94
Relief And Regulating Valves
2/15 99
95
Relief Valve Aperture
2/15 99
96
Oil Pressure Regulating Valve Location
2/15 99
97
Oil Cooler And Filter Assembly
2/15 99
98
Oil Cooler Assembly
2/15 99
99
Oil Cooler Exploded View
2/15 99
100
Oil Cooler Pressure Test
2/15 99
101
Oil Filter Bypass Valve
Normal Flow Restricted Flow

2/15 99
102
Oil Temperature Control Valve
2/15 99
103
Oil Temperature Control
2/15 99
104
Oil Filter / Cooler / Filter Header Oil Flow
2/15 99
105
Oil Spray Tubes
2/15 99
106
Oil Spray Tubes Installed
2/15 99
107
Series 40E
Oil Degradation
Oil Change Interval
Oxidation Increased Viscosity, Hard Starting

Additive Depletion Increased Wear and
Deposits
Combustion Products All of the Above
Oil Degradation is Affected by Engine Operating

Time, Fuel Rate and Oil API Classification
2/15 99
108
Series 40E
SAE Viscosity Grades
30
20W-40
15W-40 PREFERRED
PREFERRED 10W-30
5W-30
0W-30
F -20 -10 0 10 20 30 40 50 60 70 80 90 100
C -30
Series 40E25ST0041/2 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35 40
2/15 99
109
Series 40E
Oil Change Intervals
19,300 km (12,000 miles)
450 Hours
6 Months
Oil Capacity
22.7 L (24 quarts) without filter change
26.4 L (28 quarts) with filter change
Sulfur Content of Fuel Oil Change Interval
Below 0.5% Normal

0.5% to 1.0% 3/4 Normal
Above 1.0% 1/2 Normal
2/15 99
110
COOLING SYSTEM
FEATURES AND BENEFITS
WATER PUMP
BELT DRIVEN (SERPENTINE)
THREE RATIOS INDEPENDENT OF FAN SPEED
1:3:1
1:5:1
1:8:1
DEPENDENT ON ENGINE HP
RATING AND APPLICATION
2/15 99
112
COOLANT SYSTEM FLOW
2/15 99
113
WATER PUMP POSITION
2/15 99
114
WATER PUMP ASSEMBLY
2/15 99
115
WATER PUMP - DAMAGED
2/15 99
116
Series 40E
Water Pump Sub Assembly
Water Pump
Water Pump
Seal Assembly
Impeller Assembly
Fan And Pulley Hub
Bearing Shaft
Water Pump Housing

2/15 99
117
THERMOSTAT POSITION
2/15 99
118
Series 40E
Thermostat Operation
Out To
Radiator
O-Ring
In From
Engine
In From
Engine
Thermostat Thermostat
In Open In Closed
Position Position
Coolant To By-Pass Open,
Radiator Recirculation
By-Pass To To Water Pump
Series 40E25ST0041/2 By-Pass
2/15 99
Closed
Water Pump
119
COOLANT FILTER
2/15 99
120
Series 40E
Coolant Filter With Check Valve
Valve Spring
Valve Cage Check Valve

Assembly
Valve Body
Valve Disk Outlet

Filter Element
2/15 99 Inlet
121
FREEZE PROTECTION
REFRACTOMETER HYDROMETER
PG & EG EG ONLY
2/15 99
122
FUEL SYSTEM
Series 40E
Injection Control System
2/15 99
124
Series 40E
Fuel System Flow
2/15 99
125
Series 40E
Injection Control Pressure Reservoir
2/15 99
126
Series 40E
High Pressure Oil Pump
2/15 99
127
Series 40E
Injection Control System Flow
2/15 99
128
HEUI INJECTOR
OPERATION
Series 40E
HEUI Fuel Injector
2/15 99
130
Series 40E
HEUI Injector Schematic
Poppet Valve
Intensifier
Piston
High Pressure
Plunger Oil Channel
Fuel Inlet
2/15 99
131
Series 40E
Fill Cycle
2/15 99
132
Series 40E
Solenoid Energized
2/15 99
133
Series 40E
Injection Delay
2/15 99
134
Series 40E
Main Injection
2/15 99
135
Heui_iny.exe
2/15 99
136
Series 40E
Injector Harness
2/15 99
137
ABBREVIATIONS
AND ACRONYMS
Series 40E
Abbreviations and Acronyms
APS Accelerator Position EBP Exhaust Back Pressure
Sensor Sensor
ATA American Trucking EBPR Exhaust Back Pressure
Association Regulator
BARO Barometric Pressure ECM Electronic Control

Sensor Module
BNO Brake Normally Open ECI Engine Crank Inhibit
Switch
CMP Camshaft Position Sensor ECT Engine Coolant
Temperature Sensor
COL Change Oil Lamp EOP Engine Oil Pressure Sensor
DDS Driveline Disengagement EOT Engine Oil Temperature
Series 40E25ST0041/2 Switch Sensor
2/15 99
139
Series 40E
Abbreviations and Acronyms
EST Electronic Service Tool IVS Idle Validation Switch
HEUI Hydraulically Activated MAP Manifold Absolute Pressure

Electronically Controlled Sensor
Unit Injector
NPS Neutral Position Switch
HPG Hydraulic Pressure
Governing OCP Overcrank Protection
IAT Intake Air Temperature
OWL Oil Water Warning Light
Sensor
ICP Injection control Pressure SCCS Speed Command Control
Sensor Switch
IPR Injection Pressure Regulator VREF Voltage Reference
2/15 99
140
ELECTRONIC
ENGINE CONTROL
Series 40E
Processing Information
Input Processing Outputs
2/15 99
142
Series 40E
Consolidated Engine Controller
Electronic
Control
Module
(ECM)
EEPROM
2/15 99
143
Series 40E
ECM
2/15 99
144
Series 40E
Camshaft Position Sensor
Electronic
Control
Module
(ECM)
EEPROM
2/15 99
145
Series 40E
Cam Position Sensor
2/15 99
146
Series 40E
Timing Disk
2/15 99
147
Series 40E
Cam Position Sensor
Unit
Injectors
CMP
Sensor ECM IPR
Tachometer
2/15 99
148
Series 40E
Accelerator
Position Sensor
Electronic
With Idle Validation
Control
Module
(ECM)
EEPROM
2/15 99
149
Series 40E
Accelerator Position Sensor
2/15 99
150
Series 40E
Accelerator Position Sensor
Unit
APS ECM Injectors
IPR
2/15 99
151
Series 40E
Accelerator
Position Sensor
Electronic
Control
Injection Control Pressure
Module
(ECM)
EEPROM
2/15 99
152
Series 40E
Injection Control Pressure Sensor
2/15 99
153
Series 40E
Injection Control Pressure Sensor
Unit
Injectors
ICP
Sensor ECM IPR
Engine
Warning
Lamp
2/15 99
154
Series 40E
Accelerator
Position Sensor
Electronic
Control
Module
Manifold Absolute Pressure
(ECM)
EEPROM
2/15 99
155
Series 40E
Manifold Absolute Pressure Sensor
2/15 99
156
Series 40E
Manifold Absolute Pressure Sensor
Input Processing Output
MAP Unit
Sensor ECM
Injectors
2/15 99
157
Series 40E
Accelerator
Position Sensor
Electronic
Control
Module
Barometric Pressure (ECM)
EEPROM
2/15 99
158
Series 40E
Barometric Pressure Sensor
2/15 99
159
Series 40E
Barometric Pressure Sensor
Unit
BARO Injectors
Sensor ECM
IPR
2/15 99
160
Series 40E
Accelerator
Position Sensor
Electronic
Control
Module
Oil Pressure
EEPROM
2/15 99
161
Series 40E
Engine Oil Pressure Sensor
2/15 99
162
Series 40E
Engine Oil Pressure Sensor
Unit
Injectors
Engine
Warning
Lamp
EOP
Sensor ECM Warning
Buzzer
Oil / Water
Lamp
Oil Pressure
Gauge
2/15 99
163
Series 40E
Accelerator
Position Sensor
Electronic
Control
Module
Oil Pressure
Oil / Coolant Temperature
EEPROM
2/15 99
164
Series 40E
Engine Oil Temperature Sensor
2/15 99
165
Series 40E
Engine Oil Temperature Sensor
Unit
Injectors
EOT
Sensor ECM IPR
Oil
Temperature
Gauge
2/15 99
166
Series 40E
Engine Coolant Temperature Sensor
2/15 99
167
Series 40E
Engine Coolant Temperature Sensor
Unit
Injectors
Engine
Warning
Lamp
ECT
Sensor ECM Warning
Buzzer
Oil / Water
Lamp
Water
Temperature
2/15 99
Gauge
168
Series 40E
Accelerator
Position Sensor
Electronic
Control
Module
Oil Pressure
EEPROM
Air Temperature Sensor
2/15 99
169
Series 40E
Intake Air Temperature Sensor
2/15 99
170
Series 40E
Intake Air Temperature Sensor
Unit
IAT ECM Injectors
IPR
2/15 99
171
Series 40E
Accelerator
Position Sensor
Electronic
Control
Module
Oil Pressure
EEPROM
Coolant Level
2/15 99
172
Series 40E
Coolant Level Sensor
2/15 99
173
Series 40E
Grounding / Voltage Divider Switches
2/15 99
174
Series 40E
Accelerator
Position Sensor
Electronic
Control
Module
Oil Pressure
EEPROM
Coolant Level
VSG Control
2/15 99
175
Series 40E
Variable Speed Governor Throttle Control
2/15 99
176
Series 40E
Circuits 545 & 541
Bulkhead VIH-to-ECM
Connector Connector
Resume / Increase
Speed
545 10/K 545 31
544
541 541
11/L 32
Set / Decrease
Speed
2/15 99
177
Series 40E
Accelerator
Position Sensor
Electronic
Control
Module
Oil Pressure
EEPROM
Coolant Level
VSG Control
Hydraulic Pressure Governor

2/15 99
178
Series 40E
Hydraulic Pressure Governing Application
2/15 99
179
Series 40E
Hydraulic Pressure Governing Sensor
Input Processing Output
HPG Unit
ECM
Injectors
2/15 99
180
Series 40E
Accelerator
Position Sensor
Electronic
Control
Module
Oil Pressure
EEPROM
Coolant Level
VSG Control
Hydraulic Pressure Governor

2/15 99
Diagnostic Self Test
Request Input
181
Series 40E
Self Test Input Switch
2/15 99
182
Series 40E
Accelerator
Position Sensor
Electronic
Control
Module
Oil Pressure
EEPROM
Coolant Level
VSG Control
- +
Hydraulic Pressure Governor Battery
2/15 99
Request Input
183
Series 40E
Power Supply and Return System
2/15 99
184
Series 40E
Accelerator
Position Sensor
Electronic
Control
Module
Oil Pressure
EEPROM
Coolant Level
VSG Control
- + Cruise/PTO Control
Hydraulic Pressure Governor Battery Vehicle Speed Limiting
2/15 99
Vehicle Speed Sensor
Request Input
185
Series 40E
2/15 99
186
Series 40E
Gauges
VSS ECM
Unit
Injectors
2/15 99
187
Series 40E
Accelerator
Position Sensor
Electronic
Control
Module
Oil Pressure
EEPROM
Coolant Level
Check
VSG Control Engine
2/15 99
Request Input
188
Series 40E
Check Engine Lamp
2/15 99
189
Series 40E
Accelerator
Position Sensor
Electronic
Control
Module
Oil Pressure
EEPROM

Stop
Coolant Level Engine
Check
VSG Control Engine
2/15 99
Request Input
190
Series 40E
Stop Engine Lamp
2/15 99
191
Series 40E
Accelerator
Position Sensor
Electronic
Control
Module
Oil Pressure
EEPROM
Service
Engine
Stop
Check
VSG Control Engine
2/15 99
Request Input
192
Series 40E
Service Engine Lamp
2/15 99
193
Series 40E
Accelerator
Position Sensor
Electronic
Control
Module
Oil Pressure
Oil / Coolant Temperature Injection Pressure Regulator
EEPROM
Service
Engine
Stop
Check
VSG Control Engine
2/15 99
Request Input
194
Series 40E
Injection Pressure Regulator
2/15 99
195
Series 40E
Injection Pressure Regulator
Inputs Processing Output
ICP
Sensor
EOT
Sensor
CMP
Sensor
ECM IPR
APS / IVS
MAP
BARO
Series 40E25ST0041/2 IAT

2/15 99
196
Series 40E
Accelerator
Position Sensor
Electronic
Control
Module
Oil Pressure
EST Interface
EEPROM
Service
Engine
Stop
Check
VSG Control Engine
2/15 99
Request Input
197
Series 40E
EST Interface
2/15 99
198
Series 40E
Accelerator
Position Sensor
Electronic
Control
Module
Communication, Engine Data Line
Oil Pressure
EST Interface
EEPROM
Service
Engine
Stop
Check
VSG Control Engine
2/15 99
Request Input
199
Series 40E
Engine Data Line
Engine Vehicle Components

Control Module Control Module
2/15 99
200
Series 40E
Accelerator
Position Sensor
Electronic
Control
Module
Barometric Pressure (ECM) Engine Crank Inhibit Relay
Oil Pressure
EST Interface
EEPROM
Service
Engine
Stop
Check
VSG Control Engine
2/15 99
Request Input
201
Series 40E
Engine Crank Inhibit Relay Circuit
Ignition
DDS Switch
30 85
Engine Crank
Inhibit Relay
86
87A 87
Start
ECM
Relay
2/15 99
202
Series 40E
Accelerator
Position Sensor
Electronic
Control
Injection Control Pressure (VRE) Vehicle Retarder
Module
Oil Pressure
EST Interface
EEPROM
Service
Engine
Stop
Check
VSG Control Engine
2/15 99
Request Input
203
Series 40E
Vehicle Retarder
Engine Vehicle Retarder

Control Module Relay or Solenoid
2/15 99
204
Series 40E
Accelerator
Position Sensor
Electronic
Control Fan Controls
Module
Oil Pressure
EST Interface
EEPROM
Service
Engine
Stop
Check
VSG Control Engine
2/15 99
Request Input
205
Series 40E
Fan / Shutter Control
Engine Vehicle Fan / Shutter

Control Module Relay or Solenoid
2/15 99
206
Series 40E
HEUI
Accelerator
Position Sensor
Electronic
Module
Oil Pressure
EST Interface
EEPROM
Service
Engine
Stop
Check
VSG Control Engine
2/15 99
Request Input
207
Series 40E
ECM Control Of Injectors
EOP
CMP ECT Engine Coolant
ECM
Temperature Sensor
ECM Electronic Control Module
IPR Injection Pressure
IPR
Regulator
ECT
ICP Injection Control Pressure
ICP MAP Manifold Absolute Pressure
Sensor
EOT
EOT Engine Oil Temperature
Sensor
EOP Engine Oil Pressure Sensor
Injectors CMP Camshaft Position Sensor
MAP
2/15 99
208
Series 40E
HEUI
Accelerator
Position Sensor
Electronic
Module
Oil Pressure
EST Interface
EEPROM
Service
Engine
Stop
Check
VSG Control Engine
2/15 99
Request Input
209
WIRING
FEATURES
Series 40E
Wiring Features
The electronic control system requires
different voltage values to operate.
5 volts
Sensor inputs
12 / 24 volts
Vehicle charging system
100+ volts
Injector solenoid operation
2/15 99
211
Series 40E
Wire 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
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
25 + .25 mm for every 300 mm
1830 and greater
increment greater than 1830 mm
2/15 99
212
Series 40E
Conduit 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
213
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
214
Series 40E
Engine Harness
EOP
CMP
ECM
Sensor Input To The
ECM
Drive Injector
IPR ECT
Solenoids
ICP
EOT
Injectors
MAP
2/15 99
215
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
216
WIRE CRIMPING
EXERCISE
Series 40E
Terminal Installation Technique
Part Number Description Installation Refer to
Technique Section
1689464C1 ATS Connector Terminal A 3.7.4.1
2003343C1 BAPS Connector Terminal B 3.7.4.2
Packard 12020156 Main Power Relay Terminal A 3.7.4.1
2041419C1 VIH-to-ECM Connector Terminal C 3.7.4.3
2041420C1 VIH-to-ECM Connector Terminal C 3.7.4.3

Packard 12066614 Main Power Relay Terminal A 3.7.4.1
12103881 HPS Connector Terminal B 3.7.4.2
235135053 J1708 / J1587 Data Link Terminal D 3.7.4.4

23516830
23515462
2/15 99
Main VIH Connector Terminal
* 3.11.3.1
218
Series 40E
Push To Seat Terminal
Terminal
Connector Assembly
Terminal Lock
2/15 99
219
Series 40E
Seal Positioning Push To Seat Terminals
2/15 99
220
Series 40E
Push To Seat Terminals
Contact Insulation Wings
Cable Core Wings Seal
2/15 99
221
Series 40E
Push To Seat Terminals
Cable
Terminal Seal
2/15 99
222
Series 40E
Pull To Seat Terminal
Seal
Pull-To-Seat
Connector
2/15 99
223
Series 40E
Pull To Seat Terminal
J 38706
Or Equivalent
Cable
Terminal
2/15 99
224
Series 40E
Crimp Tool for Augat Terminals
2/15 99
225
Series 40E
Pull-to-Seat Terminal Method C
18 ga GXL Wire
16 ga GXL Wire
Terminal (14 and 16 ga Wire), 14 ga GXL Wire

P/N: 2041420C1
Terminal (18 ga Wire),
P/N: 2041419C1
2/15 99
226
Series 40E
Guidelines for Acceptable Terminal Crimp
60-pin Terminal Detail Crimp Height Crimp Width

14 AWG Insulation 3.22 mm 3.48 mm
14 AWG Conductor 1.50 mm 2.44 mm
16 AWG Conductor 1.34 mm 2.44 mm

1.24 mm
18 AWG Conductor 2.05 mm
2/15 99
227
Series 40E
Deutsch Terminal Positioning
0.8 mm
6.0 mm
2/15 99
228
Series 40E
Deutsch Terminal Installation
25.4 mm
2/15 99
229
Series 40E
Deutsch Terminal
Unlocked Position Locked Position
2/15 99
230
Series 40E
Deutsch Removal Tool
2/15 99
231
Series 40E
Cannon Connector Crimp Tool
Latch
Crimp Tool
Locator
Latch
Locator
Locator
Color
Code Turret
Index
Mark
Lock Pin
Series 40E25ST0041/2 Dial
2/15 99
232
Series 40E
Cannon Connector
2/15 99
233
Series 40E
Cannon Connector Exploded View (Plug End)
2/15 99
234
Series 40E
Cannon Exploded View (Socket End)
2/15 99
235
Series 40E
Cannon Terminal Insertion
Insertion
Tool
Guide Pin
Shoulder
2/15 99
236
Series 40E
Cannon Connector Removal Tool
Socket
Extraction End
Handle
Lock Ring
Pin Extraction End

2/15 99
237
WIRE SPLICING
GUIDELINES
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
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239
Series 40E
Splicing Straight Leads
Clip
2/15 99
240
Series 40E
Recommended Splicing Tools Alt. Method 1
Tool Part Number

Heat Gun ----
Wire Stripper Kent-Moore J-35615 or equivalent
Splice Clips 23519359 or equivalent

Terminal Crimper for 16 and 18 AWG Kent-Moore J-38125-6
Terminal Crimper for 14 and 12 AWG
Terminal Crimper for 10 AWG

2/15 99
241
Series 40E
Splicing Straight Leads Alt. Method 1
2/15 99
242
Series 40E
Recommended Splicing Tools Alt. Method 2
Tool Part Number

Heat Gun ----
Wire Stripper Kent-Moore J-35615 or equivalent
Splice Clips 0597428 or equivalent

Terminal Crimper for 16 and 18 AWG Kent-Moore J-38125-6
Terminal Crimper for 14 and 12 AWG
Terminal Crimper for 10 AWG

2/15 99
243
Series 40E
Splicing Straight Leads Alt. Method 2
Splice Clip, P/N 597428
or Equivalent
Shrink Tubing
6mm (.25) Min.

Both Ends
2/15 99
244
Series 40E
Strain Relief of Spliced Joint
Apply Two
Layers of Tape
45 mm 25 mm
Minimum Minimum
Generic
Both Ends Both Ends
Insulated
Splice Area
2/15 99
245
Series 40E
Staggering Wire Splices
65 mm Minimum Correct Method Tape Spliced

Between Splices
Wires Together
2/15 99
Incorrect Method
246
Series 40E
Shrink Wrap
The Heat Shrink Wrap must overlap the wire
insulation by about 6mm on both sides of the splice
2/15 99
247
DIGITAL
MULTIMETER
Series 40E
Digital Multimeter
Analog Multimeters are not
suitable for diagnostic work
on Navistar electronics
2/15 99
249
Series 40E
Digital Multimeter Display
Touch Hold
Manual Range
Measurement
Replace Units
Battery
Range Indicator
Zero Function
2/15 99
250
Series 40E
DVOM Pushbuttons
Manual / Auto
Zero Function
Range Select
Smooth / Backlight
2/15 99
251
Series 40E
Current Measurement
2/15 99
252
Series 40E
Voltage Measurement
2/15 99
253
Series 40E
Resistance Measurement
2/15 99
254
ELECTRONIC
SERVICE TOOL
Series 40E
Electronic Service Tool
2/15 99
256
Series 40E
Electronic Service Tool Map
2/15 99
257
ENGINE
DIAGNOSTICS
HARD START / NO START
Series 40E
Diagnostics Preparation
2/15 99
259
Series 40E
2/15 99
260
Series 40E
D-200 Test Kit
2/15 99
261
Series 40E
Fuel Quality
1. Sufficient Clean Fuel

Free of Water-Icing and clouding
Correct grade of fuel
Method Check
Visual
2/15 99
262
Series 40E
Visual Inspection
2. Visual Inspection
Inspect for leaks
Inspect for loose connections, etc.
Fuel Oil Coolant Electrical Air
Method Check
Visual
2/15 99
263
Series 40E
Engine Oil Level
3. CHECK ENGINE OIL LEVEL

Check engine crankcase oil level
Check for contaminants (fuel, coolant)
Correct Grade / Viscosity
Miles / Hours on oil
Check oil pressure on dash gauge
Method Check
Visual
2/15 99
264
Series 40E
Intake / Exhaust Restriction
4. Intake / Exhaust Restriction

Inspect hoses and piping
Check filter minder
Inspect exhaust system
Method Check
Visual
2/15 99
265
Series 40E
Inlet Restriction Gauge
2/15 99
266
Series 40E
EST Tool Fault Codes
5. EST TOOL - FAULT CODES

Install Electronic Service Tool
Active
Inactive
See Electronic Diagnostic Form for codes
2/15 99
267
Series 40E
Engine Off Tests
6a. EST - ENGINE OFF TESTS

Select Standard Test from the Engine Off Test Menu
Faults
Found
Repair fault codes before continuing
2/15 99
268
Series 40E
Injector Buzz Test
6b. EST - INJECTOR BUZZ TEST

NOTE: Standard Test must be performed first, in order to gain
access to the Injector Buzz Test.
Select Injector Test from the Engine Off Test Menu
Faults
Found

2/15 99
269
Series 40E
Flash Codes
7. STI BUTTON - FLASH CODES

NOTE: Perform this test if a EST is not available or is
inoperative
Depress and hold Engine Diagnostics switch, then turn

the ignition switch to the ON position.
Faults
Found
Refer to Electronic Diagnostic form if fault code(s) are set

2/15 99
270
Series 40E
2/15 99
271
Series 40E
EST - Data List
8. EST TOOL - DATA LIST
Select and enter the following data as the first 3 lines in a custom data list.
Monitor the data while cranking the engine for 20 seconds minimum
Data Spec Actual

Bat voltage 7 volts min.
Eng. RPM 130 RPM min.

ICP pressure 500 PSI min.
If voltage is low, refer to ECM diagnostics
If no RPM is noted recheck fault codes
If ICP pressure is low, refer to Test 10
2/15 99
272
Series 40E
ECM Voltage
9a. ECM VOLTAGE

inoperative
Check while cranking the engine
Measure with DVOM at three locations with breakout box connected at chassis harness connector on ECM
Pins: (21+ & 1-) (22+ & 2-) (24+ & 23-)
Instrument Spec Actual

DVOM & 7 volts
Breakout box minimum
2/15 99 If voltage is low, refer to ECM diagnostics
273
Series 40E
ECM Voltage
2/15 99
274
Series 40E
Engine Cranking RPM
9b. ENGINE CRANKING RPM

Minimum 130 RPM engine cranking speed for 20 seconds
Measure with breakout box engine harness on ECM @ pins 51+ & 19-

DVOM 26 Hz
51+ & 19- Minimum
If no frequency, recheck fault codes

2/15 99
275
Series 40E
Engine Cranking RPM
2/15 99
276
Series 40E
9c. Injection Control Pressure

Minimum 130 RPM crank speed for 20 seconds
Measure with breakout box connected to Engine Harness on ECM @ pins 16+ & 19- or
breakout tee signal (green) & ground (black)

DVOM 1 volt
16+ & 19- Minimum
If ICP pressure is low, refer to Test 10

2/15 99
277
Series 40E
2/15 99
278
Series 40E
J-43103
2/15 99
279
Series 40E
Low ICP Pressure Test
10. LOW ICP PRESSURE TEST
Remove EOT sensor and check for oil in reservoir and reinstall EOT
Remove high pressure hose from oil manifold
Attach adapter and ICP sensor to the hose
Monitor pressure while cranking engine

EST 500 PSI min.
DVOM 1 volt min.
If pressure is within specifications check for high pressure oil leak
if pressure is still low verify that the pump is rotating
If pressure is still low replace IPR and retest
2/15 99
280
Series 40E
Oil Reservoir Check
2/15 99
281
Series 40E
Fuel Pump Pressure (Cranking)
11. Fuel Pump Pressure

Measure at bleeder valve on filter head
Minimum 130 RPM crank speed for 20 seconds

0 - 160 PSI 20 PSI
Gauge minimum
If pressure is low, replace fuel filter, clean fuel strainer and retest
If pressure is still low, perform Transfer Pump Restriction Test 2b (of Performance
Diagnostics)
2/15 99
282
Series 40E
Fuel Pump Pressure (Cranking)
2/15 99
283
ENGINE
DIAGNOSTICS
PERFORMANCE DIAGNOSTICS
Series 40E
2/15 99
285
Series 40E
D-200 Test Kit
2/15 99
286
Series 40E
Engine Oil Level
1. CHECK ENGINE OIL LEVEL

Check engine crankcase oil level
Check for contaminants (fuel, coolant)
Correct Grade / Viscosity
Method Check
Visual
2/15 99
287
Series 40E
Sufficient Fuel / Pressure
2. SUFFICIENT FUEL / PRESSURE

Drain sample from tank(s)
Inspect fuel for contamination
Measure fuel pressure at fuel filter bleeder
Measure pressure at high idle

30 PSI
0 - 160 PSI
minimum
Gauge
@ High idle
If pressure is low replace fuel filter, clean fuel strainer and retest
If pressure is still low, proceed with step 2b
2/15 99
288
Series 40E
Transfer Pump Restriction
2b. TRANSFER PUMP RESTRICTION
Measure at fuel filter inlet @ High idle
0 - 30 Hg Less than
Vacuum gauge 8 Hg
If restriction is high, check for blockage between pump and fuel tank.
If restriction is < 8 Hg., refer to Diagnostic Manual 11-10
2/15 99
289
Series 40E
Transfer Pump Restriction
2/15 99
290
Series 40E
EST Tool Fault Codes
3. EST TOOL - FAULT CODES

Install Electronic Service Tool
Active
Inactive
2/15 99
291
Series 40E
Engine Off Tests
4a. EST - ENGINE OFF TESTS

Select Standard Test from the Engine Off Test Menu
Faults
Found
Repair fault codes, before continuing
2/15 99
292
Series 40E
Injector Buzz Test
4b. EST - INJECTOR BUZZ TEST

NOTE: Standard Test must be performed first, in order to gain
access to the Injector Buzz Test.
Select Injector Test from the Engine Off Test Menu
Faults
Found

2/15 99
293
Series 40E
Flash Codes
5. STI BUTTON - FLASH CODES

inoperative
Depress and hold Engine Diagnostics switch, then turn

the ignition switch to the ON position.
Faults
Found

2/15 99
294
Series 40E
2/15 99
295
Series 40E
Intake Restriction
6. INTAKE RESTRICTION
Measure at High idle and no load
Use manometer or magnehelic
Manometer or
12.5 H2O
Magnehelic
2/15 99
296
Series 40E
Engine Running Test
7a. EST - ENGINE RUNNING TEST

Select Standard Test from the Engine Running Test Menu
Faults
Found
2/15 99
297
Series 40E
Injector Test (Cylinder Contribution)
7b. EST TOOL - INJECTOR TEST

NOTE: Standard Test must be performed first, in order to
gain access to the Injector Test.
Select Injector Test from the Engine Running Menu
Faults
Found

2/15 99
298
Series 40E
Fuel Pressure Full Load
8. FUEL PRESSURE (FULL LOAD)

Measure fuel pressure at fuel filter bleeder
Measure pressure at full load rated speed

0 - 160 PSI 30 PSI
Gauge minimum
If pressure is low replace fuel filter, clean fuel strainer and retest
If pressure is still low perform test 2B
2/15 99
299
Series 40E
Fuel Pump Pressure Full Load
2/15 99
300
Series 40E
9. ICP PRESSURE
Monitor ICP pressure and engine RPM with the EST tool
in data list mode. Or use breakout tee and DVOM
Data Spec Actual

Low Idle PSI / volts
High Idle PSI / volts

Full Load PSI / volts
If pressure is low or unstable disconnect ICP sensor and retest
If problem is resolved, refer to ICP diagnosis
If pressure is still low or unstable, replace IPR and retest
2/15 99
301
Series 40E
J-43103
2/15 99
302
Series 40E
Boost Pressure
10. BOOST PRESSURE

Monitor boost pressure and engine RPM with the EST tool in data list mode.
Or use dash tach and 0 - 30 PSI gauge and T if EST tool is not available
Measure at full load rated speed
Spec Actual
PSI @ RPM
2/15 99
303
Series 40E
Boost Pressure
2/15 99
304
Series 40E
Crankcase Pressure
11. CRANKCASE PRESSURE

Measure at road draft tube with orifice tool J-39267
Measure at High Idle no load RPM

0 - 60 H20
Magnehelic < 8 H20
Gauge
2/15 99
305
Series 40E
Crankcase Pressure
2/15 99
306
Series 40E
Performance Diagnostics
STOP
If guideline data was obtained during the first 11 tests,

engine operation is satisfactory. No further testing is
required
2/15 99
307
Series 40E
Wastegate Actuator
12. WASTEGATE ACTUATOR

Apply regulated supply to actuator
Inspect for leakage
Inspect movement

0 - 60 PSI
28 2 PSI
Gauge
2/15 99
308
Series 40E
Wastegate Actuator
2/15 99
309
Series 40E
Exhaust Restriction
13. EXHAUST RESTRICTION

Visually inspect exhaust system for damage
Measure at a point 3 to 6 inches after turbo outlet
Measure at full load & rated speed

Magnehelic < 33 H20
0 - 60 H20
2/15 99
310
Series 40E
Exhaust Restriction
2/15 99
311
Series 40E
Valve Clearance
14. VALVE CLEARANCE

Engine off: Hot or Cold

Feeler gauge
2/15 99
312
Series 40E
Valve Adjustment
Crankshaft Position Adjust Valves
INT EXH INT EXH INT EXH
#1 Piston at TDC Compression
1 2 3 6 7 10
#6 Piston at TDC Compression EXH INT EXH INT INT EXH
4 5 8 9 11 12
Front
2/15 99
313

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INTRODUCTION

Overhaul / Electronics and Diagnostics

Starting Engine Serial Number:

Stamped on pad located on crankcase left side

Fuel Supply High Pressure Oil

Normal Flow Restricted Flow

Oxidation Increased Viscosity, Hard Starting

Oil Degradation is Affected by Engine Operating

F -20 -10 0 10 20 30 40 50 60 70 80 90 100

Below 0.5% Normal

Water Pump Housing

Valve Cage Check Valve

Valve Disk Outlet

BARO Barometric Pressure ECM Electronic Control

HEUI Hydraulically Activated MAP Manifold Absolute Pressure

IPR Injection Pressure Regulator VREF Voltage Reference

Input Processing Outputs

Input Processing Outputs

Input Processing Outputs

Input Processing Outputs

Input Processing Output

Input Processing Outputs

Input Processing Outputs

Air Temperature Sensor

Input Processing Outputs

Air Temperature Sensor

Air Temperature Sensor

Air Temperature Sensor

Hydraulic Pressure Governor

Input Processing Output

Air Temperature Sensor

Hydraulic Pressure Governor

Air Temperature Sensor

Air Temperature Sensor

Input Processing Outputs

Air Temperature Sensor

Air Temperature Sensor

Series 40E25ST0041/2 IAT

Engine Vehicle Components

Engine Vehicle Retarder

Engine Vehicle Fan / Shutter

Wire Gauge Must Withstand Applied Load

2003343C1 BAPS Connector Terminal B 3.7.4.2

Packard 12020156 Main Power Relay Terminal A 3.7.4.1

2041419C1 VIH-to-ECM Connector Terminal C 3.7.4.3

2041420C1 VIH-to-ECM Connector Terminal C 3.7.4.3

12103881 HPS Connector Terminal B 3.7.4.2

235135053 J1708 / J1587 Data Link Terminal D 3.7.4.4

Cable Core Wings Seal

Terminal (14 and 16 ga Wire), 14 ga GXL Wire

60-pin Terminal Detail Crimp Height Crimp Width

14 AWG Conductor 1.50 mm 2.44 mm

16 AWG Insulation 2.90 mm 3.48 mm

16 AWG Conductor 1.34 mm 2.44 mm

18 AWG Insulation 2.59 mm 2.84 mm

Unlocked Position Locked Position

Pin Extraction End

Tool Part Number

Tool Part Number

Wire Stripper Kent-Moore J-35615 or equivalent

Splice Clips 23519359 or equivalent

Terminal Crimper for 14 and 12 AWG

Terminal Crimper for 10 AWG

Tool Part Number