V alve cover - Install

3040 CVT Boomer™ 3045 CVT Boomer™ 3050 CVT

Prior operation: V alve drive and gears - Clearance alves) (10.106)

Install a new gasket (1) and position the valve cover (2) over the rocker

Install the valve cover retaining bolts (3) , and tighten - N·m ( 9 - )

Install and tighten the seal washer (4) , and cap nuts (5)

Next operation: W ater pump - Install (with Cooling Fan)

Engine - Cylinder heads

Cylinder head - Compression test

Boomer™ 3040 CVT

Boomer™ 3045 CVT

Boomer™ 3050 CVT

Compression test performed through the glow plug The test adapter tool (1) , equipped with quick coupler ends for easy installation the hose and

The procedures perform a compression test are follows:

Remove the wire lead from the fuel injection pump

Remove the glow plug electrical wire and wire tor from top the glow

Remove all the glow

NOTE: Be sure all the glow plugs are removed before starting the compression Install the adapter T ool FNH00120 , hose and gauge assembly OEM1074 (2) , each port and crank the engine until pressure The gauge should read 2944 kPa ( 427 psi ) ) plus minus 345 kPa ( psi )

NOTE: may necessary remove some injector fuel lines install the adapter tool.

NOTE: There should not more than 345 kPa ( psi ) variation between the cylinders. When all cylinders have been tested, reinstall the glow plugs and electrical

Engine - Cylinder heads

Cylinder head - Remove

Boomer™ 3040 CVT

Boomer™ 3045 CVT

Boomer™ 3050 CVT

Prior operation:

Rocker Arm Shaft and Support Bracket - Remove; See: Disassemble”..

Remove the valve stem caps (1) , and push rods (2)

T o remove the cylinder remove the cylinder head bolts (3) , alternately loosening a half turn a time prevent warping the

NOTE: Keep all valve components separately marked containers for reassembly their original

Next operation:

V alve T appet - Removal; See: Disassemble”.

Cylinder head - Inspect

Boomer™ 3040 CVT

Boomer™ 3045 CVT

Boomer™ 3050 CVT

Prior operation:

Crankcase gears - Remove - with Camshaft 14)

Disassembly

Clean the cylinder head and remove any carbon deposits from around the valve

Use a valve spring compressor and remove the valve spring retainer locks (1) , spring (2) , and spring retainer (3) , from each valve (4)

Remove the valves and place the valve nents together separately marked containers for reassembly their original

Inspection and Repair

Clean all carbon deposits from the combustion chamber and valve ports using a wire brush and scraper .

Clean all dirt and residue from the gasket surface using care not scratch nick the machined

Clean the cylinder head solvent and air dry

Inspect the head for cracks damage the lowing areas:

• V alve ports

• V alve seats (2)

• Prechamber (3) .

• External cracks the water jackets (1)

Inspect the gasket surfaces for scratches nicks, which could cause

Examine the core hole plugs for rust signs a plug shows signs damaging rust replace all plugs the

Inspect the prechamber for carbon deposits and Remove any carbon deposits prechamber found cylinder head may

• Use a straight edge and a feeler gauge and check the cylinder head for warp lengthwise, crosswise, and diagonally 20093371F

Next operation: V alve drive and gears - Inspect - V alve Seats (10.106)

Engine - Cylinder heads

Cylinder head - Replace (Gasket)

Boomer™ 3040 CVT

Boomer™ 3045 CVT

Boomer™ 3050 CVT

During assembly , the ultimate engine compression ratio established the thickness the head gasket For service head gaskets dif ferent thickness are The correct head gasket must selected based upon the amount the piston protrudes above the face the block when top dead center The correct head gasket usage determined follows:

Head Gasket Selection

Position each the pistons top dead center ing a dial indicator , determine the distance each piston projects above the face the

NOTE: Measure each the pistons while holding a slight down pressure the Use the dimension taken from the cylinder which has the greatest projection and lect a head gasket indicated the following

NOTE: The variation the amount protrusion among all pistons must within 0.1 ( 0.004 ) .

Selection Chart

Cylinder head - Assemble

Boomer™ 3040 CVT

Boomer™ 3045 CVT

Boomer™ 3050 CVT

Prior operation:

V alve drive and gears - Inspect - Push Rods

Insert each valve the guide from which was moved and lightly lap the valve sure even seat around the valve face. Remove the valve and move all traces lapping

Install new intake valve seals the valve guides using a suitable driver

Using a spring compressor , assemble the and

Next operation:

Crankcase - Inspect (10.001)

Engine - Cylinder heads

Cylinder head - Install

Prior operation:

Cylinder head - Replace (Gasket)

Install the valve tappets (1) 20093430

Select the proper head gasket and place the block with the side marked with the last four digits the part code

T ighten the head bolts the sequence

T ighten first half torque value, then the final torque specification - 103 N·m ( - )

Replace the push rods and valve stem caps their original location.

Install the rocker shaft support assembly onto the head and tighten the bolts - N·m ( - ) 20002380

Next operation: V alve drive and gears - Clearance alves)

T iming gear housing - Remove

Prior operation:

Engine block cover Front - Remove (10.102)

Drain the engine crankcase

Remove the crankshaft pulley

Loosen the four injection pump mounting bolts (2) , and raise the injection pump (3) , enough remove the spring pin (1) , and separate the governor link from the control Remove the injection

Insert a small dowel (1) , through the fuel shutof f lenoid hole and slide the control rack (2) , allow enough clearance the cylinder block, for the pump

Remove the through bolts and nuts (1) , and remove the steering pump from the front cover Cap the lines and pump

NOTE: T the power steering pump retaining bolts are not

Install and tighten two nuts (1) , against each other , onto the retaining studs (2) Remove the studs (2) , and the hydraulic pump (3) 76075735 4 Remove the retaining nut (1) Pull crankshaft pulley (2) , and key (4) , f crankshaft (3) 76075736

Remove the retaining bolts (1) , and lift the cover (2) , f the locating

Next operation:

T iming gear housing - V isual inspection

Next operation:

Crankcase gears - Remove - with Camshaft (10.1 14)

Engine - Pan and covers

T

iming gear housing - V isual inspection

Prior operation: Engine flywheel - Inspect (10.103)

The timing gear housing (3) , contains the front oil seal (1) , power steering seal (4) , and the governor linkage assembly (2) See Assembly", for governor linkage repair and replacement 10044360A

Front Oil Seal and Steering Pump Seal Replacement

Remove the front oil seal (1) , from the timing gear cover (3) , and insert a new oil seal its

Remove the steering pump seal (4) , located the front the timing gear cover , and replace with a new 10044360B

Next operation: W ater pump - Inspect (10.400) .

Engine - Pan and covers

T iming gear housing - Install

Prior operation: Crankcase gears - Install (Idler Gear , Oil Pump, and Injection T iming) (10.1 14)

Install new cover

Insert the governor linkage through the Rotate the oil pump cover position the spring pin hole (2)

Install cover locating pin the oil pump cover

Install the cover retaining bolts (1)

Next operation: Crankshaft - Install (Pulley)

Engine - Pan and covers

Engine block cover Front - Remove

Remove the crankcase ventilation system (1) Refer Crankcase ventilation system - Remove (10.304) for the proper

Remove the crankshaft pulley bolts (2) .

Remove the crankshaft pulley (3)

Remove the connector for the camshaft sensor (1)

Remove the cover retaining bolts (1)

NOTE: T ake note the bolt size and

Remove the front cover (2)

Next operation: Engine block cover Front - Install

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Engine - Pan and covers

Engine block cover Front - Install

Prior operation:

Engine block cover Front - Remove

Clean the sealing surface (1) the cover

Clean the sealing surface (1) timing gear

Install the front cover (1) with a new Loosely install two bolts (2) hold everything

3

Install the crankcase ventilation drive hub (1) T orque the nut ( ) .

Install the lower alignment tool 380100280 (2) the Install the upper alignment tool 380100281 (1) onto the drive hub align the front cover .

Install the remainder the front cover retaining bolts (1)

T orque the front cover retaining bolts (1) - N·m ( - )

1 Remove the alignment

Engine - Pan and covers

Engine oil pan - Remove

NOTE: Oil pan images may vary depending your

Drain the engine

Remove the oil pan bolts (3)

Remove the oil pan retaining plate (2)

Remove the oil pan (1)

Remove the pick tube support bolts (2)

Remove the Allen head bolt (1) from the pick

Remove the pick tube (3) from the engine

Next operation: Engine oil pan - Install

Engine - Pan and covers

Engine oil pan - Install

Prior operation: Engine oil pan - Remove (10.102)

NOTE: Oil pan images may vary depending your Install a new O - ring (1) the pick tube.

NHIL14ENG0607AA 1

Install the oil pick tube (3) into the engine block until the O - ring seats.

Install the Allen head bolt (1) into the pick tube.

T orque the tube bolt (1) N·m ( 7 )

Install the two M10 x bolts (2) into the pick tube

T orque the pick tube support bolts (2) N·m ( )

Install the new gasket (1) the oil pan (2) .

NHIL14ENG0606AA 2

NHIL14ENG0609AA 3