THE ORIGINAL REPLACEMENT

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  • FORD 40 SERIES TORQUE SETTINGS

    Valve Lash Clearance (Cold)

    Exhaust

    0.017-0.021 in (0.43-0.53mm)

    Intake

    0.014-0.018 in (0.36-0.46mm)

    Piston Rings

    Gap Width

    Top Compression

    0.015-0.033 in (0.38-0.84mm)

    2nd Compression

    0.026-0.044 in (0.66-1.12mm)

    Oil Control

    0.015-0.033 in (0.38-0.84mm)

    Crank Journal Diameter

    Main Diameter

    3.3713-3.3718 in (85.631-85.644mm)

    Big End Diameter

    2.750-2.7504 in (69.850-69.860mm)

    Crank Bolts Torque

     Lb ft

     Nm

    Mains

    145 lb ft

    197 Nm

    Rod Bolts

    110 lb ft

    149 Nm

    Head Bolts Engine Cold

    160 lb ft

    217 Nm

    Flywheel Bolts

    145 lb ft

    197 Nm

    Sump to block (Cast)

    28 lb ft

    38 Nm

  • PERKINS 1100 SERIES, 3 & 4 CYLINDER, TORQUE SETTINGS

    The Torque settings below are suitable for Perkins 1100 Series 3 and 4 cylinder engines with the following engine number prefixes.

    DC, DD, DJ, DK, RE, RG, RJ, RR, RS.

    HEAD BOLT TORQUES
    STAGE  Nm Lb Ft
    1. 50 37
    2. 100 74

    The short and Long head bolts require additional torque procedure by degree of turn, numbers 1,3 and 4 are short bolts.(see Torque sequence below).

    3.  Short Bolt
    4. Long Bolt

    Tightening Sequence

     

     

     

     

     

    Valve Clearances

    Inlet   0.20mm (0.008")

    Exhaust 0.45mm (0.018")

  • WHAT IS PLATEAU HONING

    Plateau honing is a process that improves cylinder wall surface finish by removing tiny peaks of torn or folded material and increasing bearing area. This type of finish allows lubricant to collect in the remaining valleys, improving lubrication control and retention. It also extends the life of components such as piston rings and seals because there are no peaks of material for them to remove during initial break-in.

  • EMMARK GEAR REDUCTION STARTER MOTORS

    Our gear reduction starter motors have the same part number as Direct drive Starters but with -GR added to the end of the part number so EM427 is  Direct drive and EM427-GR is gear reduction.

    Direct drive and gear reduction are the two methods that a starter can use to drive the ring gear of a flywheel.
    Direct drive came first, and it involves using a large, low speed motor to rotate a pinion gear in a 1:1 ratio.

    Then came Gear reduction and entered mainstream usage about 20 years ago.

    Unlike direct drive, gear reduction starters use smaller, faster motors to rotate their pinion gears in a roughly 4:1 ratio, which results in lower power consumption and higher torque.
    When direct drive and gear reduction starters are compared, direct drive units are typically cheaper, and gear reduction units tend to be smaller, lighter, and more efficient.
    In starters that use direct drive, the armature shaft of the starter motor is attached directly to the drive mechanism. Although “gear reduction” technically takes place between the starter’s pinion gear and the ring gear on the flywheel, the pinion gear itself rotates in a 1:1 ratio with the armature shaft.

    Gear reduction is accomplished with spur or planetary gears.
    A. Starters that use spur gears require an offset armature, this is
    achieved by placing the starter drive in a separate gear
    housing.
    B. Starters that use planetary gears can be contained in an in
    line drive-end housing.
    In either case, the armature shaft will typically rotate about four times for each rotation of the pinion gear.

    The advantage of gear reduction is that it allows for considerably smaller starters that produce a greater amount of torque in comparison to much larger direct drive starters. The main drawback is that they are typically more expensive.

  • Perkins AR (4.421) & AS (N4.421) TIGHTENING TORQUES

    The Torque settings below are suitable for Perkins Phaser 4 cylinder engines with the following engine number prefixes AR & AS.

    Check the head bolts for distortion using a straight edge along the screw if any reduction in the diameter of the thread is found they must be replaced. Please pay close attention to the bolt lengths, mark on the head of the bolts for short medium and long, stage 5 of torquing is by degree of angle. Check our online store to order replacement bolts. - See more at:

    Head Bolts Page

    Technical Details.
    Metric
    Imperial

    Head Bolt Torques

     

     

    Stage 1. All Bolts
    45Nm
    33 lb ft
    Sequence in Fig.1. Below.    

    Stage 2.
    All Bolts repeat Stage 1 to ensure all bolts correct.
    Stage 3.     
    ½ UNF in sequence 2,8,13 and 18 in Fig.1.
     110 Nm

    80 lb ft

     

    Stage 4. Repeat Stage 3.

     

       
      Stage 5. Tighten the M10 Bolts in the correct sequence a further turn
    according to the length. Short and Medium M10 see Fig.2.
    
    Fig.2.  Short and Medium

     

      Long M10 Bolts see Fig.3.
    
    Fig.3. Long
     
     The Four ½ UNF bolts see Fig.4.
    
    Fig.4.  

    Main Bearing Bolts.          265Nm             196 lb/ft.

    Conrod Bolts                     155Nm              114 lb/ft.

    Conrod Nuts                      125Nm              92 lb/ft.

    Flywheel                              105Nm              77 lb/ft.

     

    Fig .1.

     

     

     

     

     

     

     

     

    Valve Clearances                    Metric                  Imperial

    Inlet                                              0.2mm                   0.008" in

    Exhaust                                       0.45mm                   0.018" in

  • TIGHTENING TORQUES FOR PERKINS PHASER 1004

    The Torque settings below are suitable for Perkins Phaser 4 cylinder engines with the following engine number prefixes.

    AA, AB, AC, AD, AE, AF, AG, AH.

    Check the head bolts for distortion using a straight edge along the screw if any reduction in the diameter of the thread is found they must be replaced. Please pay close attention to the bolt lengths, mark on the head of the bolts for short medium and long, stage 2 of torquing is by degree of angle. Check our online store to order replacement bolts.
    Technical details. Metric Imperial
    Head Bolt Torque
    Stage 1. All bolts. 110 NM 81 lbs/ft
    Stage 2. Short Bolt short-bolt
    Stage 2. Medium Bolt medium-bolt
    Stage 2. Long Bolt long-bolt
    Main Bearing Bolts 250 NM 184 lbs/ft
    Conrod Nuts 125 NM 92 lbs/ft
    Conrod Bolts 155 NM 114 lbs/ft
    Flywheel 105 NM 77 lbs/ft

     

    Torque Sequence
    1004-sequence

     

     

     

     

     

     

     

    Valve Clearances Metric Imperial
    Inlet 0.20 mm 0.008 in
    Exhaust 0.45 mm 0.018 in

     

  • TIGHTENING TORQUES FOR PERKINS 4.236

    Technical details. Metric Imperial
    Head Torque - Nuts 7/16 in 81 NM 60 lbs/ft
    Head Torque - Nuts 1/2 in 136 NM 100 lbs/ft
    Main Bearing Bolts 203 NM 150 lbs/ft
    Conrod Bolts Black 129 NM 95 lbs/ft
    Conrod Bolts Silver 102 NM 75 lbs/ft
    Flywheel 122 NM 90 lbs/ft

    Torque Sequence

    4-236-head

    Valve Clearances
    Inlet 0.30 mm 0.012 in
    Exhaust 0.30 mm 0.012 in
  • Why should I read this blog?

    Because tips and advice for mechanics and enthusiasts alike are just around the corner!

    Welcome to our first blog post and an introduction to what?s coming up!
    At Emmark UK we believe in working with our customers to provide help and solutions to their problems by providing parts and advice. With that in mind, we are bringing together a collection of blogs which will be short and succinct but are designed to help you with engineering queries you may come across on a day to day basis.
    The blogs will be posted monthly and will cover a range of issues from where to find your engine number to best practice when fitting your pistons.
    We hope these will help you and would love to hear your feedback.

  • Measuring Piston Compression height

    The compression height of any piston is the measurement from the centre of the gudgeon pin or wrist pin as the Americans call it to the top of the crown of the piston, see below.

    piston_compression_height

    The easiest way to measure is with a pair of digital Vernier gauges, measure from the top of the pin hole to the top of the piston. Make a note of that measurement, then measure the pin diameter and half it. Add half the pin diameter to the first measurement you made a note of. This will give your compression height.
    This does not provide 100% accurate value but is close enough to assist in identifying your piston.

    Check out our next technical blog coming soon.

  • Measuring Diesel Pistons

    You might ask why do I need to measure my piston.
    Here at Emmark we are often asked the question how do I know which piston is in my engine when I don?t know the engine number.
    Assuming we know what type of engine i.e. Ford, Perkins, John Deere, Case-IH then the bore size needs to be determined, this will focus the engine type within a certain range, but then it is more than likely there will be several different engines made by each manufacturer with the same bore size, this is where we need to dimensionally measure the piston as follows.

    1. Compression Height
    2. Length
    3. Combustion Bowl
    4. Combustion Bowl Type
    5. Pin diameter
    6. Number of Rings
    7. Oil Cooled Crown
    8. Skirt Type

    All of these points we will deal with in following blogs.

    Check out our Technical blogs for any other help you may need and feel free to ask us.

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