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Old 03-23-2009, 08:07 PM
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Torque specs, Injector and IPR info I thought I would share

This is some stuff i've collected and saved up in a file on my comp, and noticed it, and thought I would throw this out there for you guys, hopefully somebody someday might find this useful information.





Valve Spring Compression
Note: Pressure lbs.@specified height Intake 71-79 lbs. @ 1.833 in
225-249 lbs. @ 1.352 in
Exhaust 71-79 lbs. @ 1.833 in
225-249 lbs. @ 1.352 in
Valve Spring Free Length (Approximate) Intake 2.075±0.150 in
Exhaust 2.075±0.150 in
Valve Spring Assembled Height Intake 1.767 in
Exhaust 1.833 in
Valve Spring Out of Square-Maximum 0.078 in

--------------

Valve Stem-to-Guide Clearance (Max) Intake 0.0055 in
Note: Service clearance-.0055.
Exhaust 0.0055 in
Note: Service clearance-.0055.
Valve Face Angle Intake 30°
Exhaust 37.5°
Valve Face Runout-TIR Maximum 0.002 in
Minimum Valve Face Margin-Intake Valves 0.066 in
Minimum Valve Face Margin-Exhaust Valves 0.054 in
Valve Stem Diameter 0.31185-0.31255 in
Valve Head Recession Relative to Deck Surface Intake 0.046-0.058 in
Exhaust 0.052-0.064 in -
-----------------------------------------------------------------------------
A/C manifold and tube retaining bolt 15 ft. lbs.
Air brake ABS module bracket assembly mounting nuts 15 ft. lbs.
Air cleaner housing mounting bolts 22 ft. lbs.
Air cleaner support bracket mounting nuts 21 ft. lbs.
Air compressor bracket mounting bolts 58 ft. lbs.
Air compressor mounting bolts 50 ft. lbs.
Air compressor mounting nuts 58 ft. lbs.
Belt tensioner mounting bolt 32 ft. lbs.
Camshaft position (CMP) sensor mounting bolt 18 ft. lbs.
Camshaft thrust plate retaining bolts 18 ft. lbs.
Connecting rod cap nuts Stage 1 53 ft.lbs. Stage 2 80 ft.lbs.
Cooling fan 74 ft. lbs.
Crankshaft rear oil seal retaining bolts 15 ft. lbs.
Crankshaft vibration dampener bolt 212 ft. lbs.
Cylinder head bolt
Note: Lightly lubricate the cylinder head bolt threads and flanges with clean engine oil.
Stage 1 65 ft. lbs. Stage 2 85 ft. lbs. Stage 3 95 ft. lbs.
Drive gear access cover retaining bolts 20 ft. lbs.
Engine front cover bolts 15 ft. lbs.
Engine rear cover bolts 15 ft. lbs.
Exhaust bracket to engine support bracket mounting bolts 37 ft. lbs.
Exhaust manifold mounting pipe nuts and bolts 45 ft. lbs.
Engine support bracket mounting bolts 76 ft. lbs.
Flywheel/Flexplate bolts 89 ft. lbs.
Front stabilizer bar mounting nuts 98 ft. lbs.
Front support bracket to engine mounting bolts 76 ft. lbs.
Front support bracket to number two crossmember mounting nuts 166 ft. lbs.
Fuel return hose 19 ft. lbs.
Fuel supply hose 37 ft. lbs.
Flexplate mounting bolt (automatic transmission) 89 ft. lbs.
Flywheel mounting bolt (manual transmission) 89 ft. lbs.
Flywheel housing mounting bolts 15 ft. lbs.
Generator and compressor mounting bracket mounting bolts A/C 36 ft. lbs.
High-pressure oil line connector (cylinder head) 19 ft. lbs.
High-pressure oil pump drive gear mounting bolt 95 ft. lbs.
High-pressure oil pump mounting bolts 18 ft. lbs.
High-pressure oil pump reservoir mounting bolts 18 ft. lbs.
Idler pulley mounting bolt 41 ft. lbs.
Intake manifold cover mounting bolts 18 ft. lbs.
Main bearing cap bolts

Stage 1 76 ft. lbs. Stage 2 96 ft. lbs.
Muffler assembly mounting nuts 37 ft. lbs.
Number two crossmember mounting bolts 66 ft. lbs.
Oil cooler retaining bolts 18 ft. lbs.
Oil level indicator tube adapter nut 24 ft. lbs.
Oil pan mounting bolts 18 ft. lbs.
Oil pump body plate bolts 15 ft. lbs.
Oil pump screen cover and tube flange bolts 18 ft. lbs.
Oil pump screen cover and tube retaining nut 38 ft. lbs.
Parking brake cable bracket mounting bolt (automatic transmission) 21 ft. lbs.
Parking brake cable clamp mounting bolts (manual transmission) 21 ft. lbs.
Power steering pressure hose 24 ft. lbs.
Power steering pump mounting nuts 41 ft. lbs.
Rear bracket to frame mounting nuts 184 ft. lbs.
Rear support cap mounting nuts 106 ft. lbs.
Rocker arm pedestal attaching bolts 20 ft. lbs.
Slave cylinder lock nut 24 ft. lbs.
Slave cylinder interlock bracket mounting bolts 44 ft. lbs.
Starter motor mounting bolts 38 ft. lbs.
Transmission oil cooler hoses 21 ft. lbs.
Transmission shift lever housing mounting bolts 40 ft. lbs.
Turbocharger exhaust inlet pipe-to-exhaust manifold bolts 21 ft. lbs.
Turbocharger mounting bolts 18 ft. lbs.
Turbocharger pedestal assembly mounting bolts 18 ft. lbs.
Water pump bolts 18 ft. lbs.
Valve cover retaining bolts and nuts 8 ft. lbs.

Grade 5 UNC Fasteners
1/4-inch 80 inch lbs.
5/16-inch 15 ft. lbs.

Grade 5 UNF Fasteners
1/4-inch 9 ft. lbs.
5/16-inch 17 ft. lbs.

Grade 8 UNC Fasteners
3/8-inch 41 ft. lbs.
7/16-inch 66 ft. lbs.
1/2-inch 96 ft. lbs.
9/16-inch 140 ft. lbs.
5/18-inch 188 ft. lbs.
3/4-inch 339 ft. lbs.
7/8-inch 550 ft. lbs.

Grade 8 UNF Fasteners
3/8-inch 44 ft. lbs.
7/16-inch 70 ft. lbs.
1/2-inch 111 ft. lbs.
9/16-inch 155 ft. lbs.
5/18-inch 214 ft. lbs.
3/4-inch 380 ft. lbs.
7/8-inch 616 ft. lbs.

Class 9.8 Metric Fasteners
M4 27 inch lbs.
M5 62 inch lbs.
M6 8 ft. lbs.
M8 20 ft. lbs.
M10 38 ft. lbs.
M12 58 ft. lbs.
M14 92 ft. lbs.
M16 142 ft. lbs.

Class 10.9 Metric Fasteners
M6 10 ft. lbs.
M8 26 ft. lbs.
M10 50 ft. lbs.
M12 74 ft. lbs.
M14 118 ft. lbs.
M16 183 ft. lbs.
M20 357 ft. lbs.
M24 618 ft. lbs.

Pipe Threads
1/8x27 80 inch lbs.
1/4x18 15 ft. lbs.
3/8x18 27 ft. lbs.
1/2x14 30 ft. lbs. -
--------------------------------------------------
Bore and Stroke 4.11 in x 4.18 in
Firing order 1-2-7-3-4-5-6-8
Oil pressure Note: Normal operating temperature @ 3,300rpm 40-70 psi
Engine type and number of cylinders V-8
Compression Ratio 17.5 to 1


IPR--
Injection Pressure regulator is controlled electronically, and actuated electrically. Actual high-pressure oil values are managed by the IPR.
It is a spool valve, positionally controlled by a pulse width modulated signal to achieve a range of injection control pressures(ICP). It operates at 400 Hertz. The ECM pressure regulating signal determines the magnetic field strength in the solenoid coil, and therefore, armature position. Integral with the armature is a poppet valve designed to control the extent to which high pressure pump oil is spilled to the drain port and therefore the pressure of the oil that is used as the hydraulic medium for actuating the HEUI’s.
HEUI’s--sub-components of a Hydraulically Actuated Electronically Controlled Unit Injector
Solenoid- The solenoid is switched by the ECM using a 100-120v coil induced voltage(from the IDM). The HEUI electrical terminals connect the solenoid coil with wiring to the ECM injector drivers.
Poppet Valve-The HEUI poppet valve is integral with the solenoid armature. It is machined with an upper and lower seat. For most of the cycle, the poppet valve seat loads the lower seat into a closed position, preventing high pressure engine oil from entering the HEUI; the upper seat is open, venting the oil actuation spill ducting. When the HEUI solenoid is energized, the poppet valve is drawn into the solenoid, opening the lower seat and admitting high pressure oil from the IPR. When the poppet valve is fully open, the upper seat seals, preventing the oil from exiting the HEUI through the spill passage.
Intensifier of Amplifier Piston- The intensifier piston is designed to actuate the injection plunger, which is located below it. When the poppet control valve is switched by the ECM to admit high pressure oil into the HEUI, the oil pressure acts on the sectional area of the intensifier piston. The actual oil pressure(managed by the ECM) determines the velocity at which the plunger located below the intensifier piston is driven into the injection pump chamber. The sectional area of the amplifier piston determines how much the actuating oil pressure is multiplied in the injection pump chamber. The intensifier piston and injection plunger are loaded into their retracted position by a spring.
Plunger and Barrel- The plunger and barrel form the HEUI pump element. The first versions of the HEUI injectors did not offer the pilot injection feature. This description will use the recently introduced HEUI with the PRIME feature. The acronym PRIME is produced from the words “preinjection metering”. As the injection plunder is driven into the pump chamber, fuel is pressurized for a short portion of the stroke, actuating and opening the injector nozzle(split shot injector). The pressure rise is of short duration because when the PRIME recess in the plunger registers with the PRIME spill port in the barrel, the pressure in the pump chamber collapses as fuel spills through the PRIME spill port. This closes the injector nozzle and injection ceases. However, the moment the PRIME recess in the plunger passes beyond the spill port, fuel is once again trapped in the pump chamber and pressure rise resumes. This results in the injector nozzle being opened for the delivery of the main portion of the fuel pulse. The fueling pulse continues until the ECM ends the effective stroke by de-energizing the HEUI solenoid. At this point, the poppet control valve is driven onto its lower seat, opening the upper seat and permitting the actuating oil to be vented. With no force acting on the intensifier piston, the plunger is driven upward by the combined force of the high-pressure fuel in the pump chamber and the plunger return spring. This causes an almost immediate collapse of pump chamber pressure and results in almost instantaneous nozzle closure.
Injector Nozzle- The HEUI injector nozzle is a multi-orifice nozzle of the VCO type that is a little different from any other injector nozzle used in a MUI or EUI assembly. A duct connects the nozzle pressure chamber with the HEUI pump chamber. A spring loads the injector nozzle valve onto its seat. The spring tension defines the nozzle opening pressure(NOP) value. When the hydraulic pressure acting on the sectional area of the nozzle valve is sufficient to overcome the spring pressure, the nozzle valve unseats, permitting fuel to pass around the nozzle seat and through the nozzle orifices.

IDM-Injector Driver Module--is responsible for switching the HEUI’s.
4 functions-
1.) Electronic distributor for the HEUI’s
2.) Powers the HEUI’s
3.) Output driver for the HEUI’s
4.) IDM and HEUI diagnostics


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2002 F-250 SCSB 4x4 6spd, full custom air ride on 38'' Nittos, hyd steer assist, forged rods, 250/100, GQSSB turbo, Stage 1 cam, Tuned by Matt, 6637, CPR+ Reg Rreturn,140v IDM, South Bend DD 3600, Excursion aux fuel tank, ATI dampner, 26925 springs, SmithBro pushrods, 08 Seats, Big intercooler, CCV, Hutch & Harpoon, and alot more.
Quote:
Originally Posted by jdecker88 View Post
Can't is not in Cory's vocabulary he's like Chuck Norris with a wrench
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  #2  
Old 03-23-2009, 08:16 PM
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That's some good info, there Cory. Thanks
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Old 03-23-2009, 08:23 PM
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No problem Huck, i'm full of useless info like that
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2002 F-250 SCSB 4x4 6spd, full custom air ride on 38'' Nittos, hyd steer assist, forged rods, 250/100, GQSSB turbo, Stage 1 cam, Tuned by Matt, 6637, CPR+ Reg Rreturn,140v IDM, South Bend DD 3600, Excursion aux fuel tank, ATI dampner, 26925 springs, SmithBro pushrods, 08 Seats, Big intercooler, CCV, Hutch & Harpoon, and alot more.
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Can't is not in Cory's vocabulary he's like Chuck Norris with a wrench
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Old 03-23-2009, 08:32 PM
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Great job man, Jim make this a sticky!
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Old 03-23-2009, 08:35 PM
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Thanks cory. Lots of torques I didn't know.
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Old 03-23-2009, 08:36 PM
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Quote:
Originally Posted by Ziggy. View Post
No problem Huck, i'm full of useless info like that
Useless to some, priceless to others.
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Old 03-23-2009, 08:51 PM
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Originally Posted by hucka1a View Post
Useless to some, priceless to others.
So you are saying info like the digital flexor tendon in a cats paw is the one that controls how deep their claws dig into your face when they latch onto you, is priceless info? your weird huck
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2002 F-250 SCSB 4x4 6spd, full custom air ride on 38'' Nittos, hyd steer assist, forged rods, 250/100, GQSSB turbo, Stage 1 cam, Tuned by Matt, 6637, CPR+ Reg Rreturn,140v IDM, South Bend DD 3600, Excursion aux fuel tank, ATI dampner, 26925 springs, SmithBro pushrods, 08 Seats, Big intercooler, CCV, Hutch & Harpoon, and alot more.
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Can't is not in Cory's vocabulary he's like Chuck Norris with a wrench
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Old 03-23-2009, 09:03 PM
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I starting to think that this motor building might be a bad idea. I thought you were a mechanic, turns out your a vet.
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Old 03-23-2009, 09:08 PM
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I starting to think that this motor building might be a bad idea. I thought you were a mechanic, turns out your a vet.
No, but when I had the dog at the vet today to get her shots I had to pick a spot on this poster on the wall to stare at, b/c I knew I would get caught looking at this female vet there and get into some trouble, to I had to stare at the poster while I was talking to her and that was the spot I picked, and I had to study it to keep my attention off her.



But don't worry, i'm still full of information like 1/16" of scale buildup in the cooling system has the same insulating effect as 4" of cast iron. So we're good to go.
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2002 F-250 SCSB 4x4 6spd, full custom air ride on 38'' Nittos, hyd steer assist, forged rods, 250/100, GQSSB turbo, Stage 1 cam, Tuned by Matt, 6637, CPR+ Reg Rreturn,140v IDM, South Bend DD 3600, Excursion aux fuel tank, ATI dampner, 26925 springs, SmithBro pushrods, 08 Seats, Big intercooler, CCV, Hutch & Harpoon, and alot more.
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Can't is not in Cory's vocabulary he's like Chuck Norris with a wrench
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Old 03-23-2009, 09:31 PM
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Ziggy what the PSI in our spare need to be.
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Old 03-23-2009, 09:32 PM
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Good excuse.lol
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Old 03-23-2009, 09:40 PM
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Quote:
Originally Posted by Bigcat350 View Post
Ziggy what the PSI in our spare need to be.
Should be 35psi bigcat
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2002 F-250 SCSB 4x4 6spd, full custom air ride on 38'' Nittos, hyd steer assist, forged rods, 250/100, GQSSB turbo, Stage 1 cam, Tuned by Matt, 6637, CPR+ Reg Rreturn,140v IDM, South Bend DD 3600, Excursion aux fuel tank, ATI dampner, 26925 springs, SmithBro pushrods, 08 Seats, Big intercooler, CCV, Hutch & Harpoon, and alot more.
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Can't is not in Cory's vocabulary he's like Chuck Norris with a wrench
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Old 03-24-2009, 06:39 AM
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Excellent Thread Cory.

I added it to our FTE guidelines mods and maint thread it is in post #2
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Old 03-24-2009, 03:33 PM
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Quote:
Originally Posted by megawatt00 View Post
Excellent Thread Cory.

I added it to our FTE guidelines mods and maint thread it is in post #2
Thank you sir, I'd like to put up some more later on when I dig around some more.
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2002 F-250 SCSB 4x4 6spd, full custom air ride on 38'' Nittos, hyd steer assist, forged rods, 250/100, GQSSB turbo, Stage 1 cam, Tuned by Matt, 6637, CPR+ Reg Rreturn,140v IDM, South Bend DD 3600, Excursion aux fuel tank, ATI dampner, 26925 springs, SmithBro pushrods, 08 Seats, Big intercooler, CCV, Hutch & Harpoon, and alot more.
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Can't is not in Cory's vocabulary he's like Chuck Norris with a wrench
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Old 05-23-2010, 10:56 AM
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Thank you Cory! I saved this to my powerstroke tech file.

Reps to for a great post.I will be using this info in the furture.

One Question is there a pattern for the head bolts to be toqured in.? As in from the center out or top to bottom.
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Old 05-23-2010, 10:56 AM
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