PRODUCT SUPPORT PROGRAM FOR THE REPLACEMENT OF THE LOW PRESSURE ACTUATORS FOR THE INTAKE VALVE ON CERTAIN C11 AND C13 TRUCK ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR THE REPLACEMENT OF THE LOW PRESSURE ACTUATORS FOR THE INTAKE VALVE ON CERTAIN C11 AND C13 TRUCK ENGINES

Usage:

REBE1743-02

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16Mar2007

(Revised 11Dec2007)

U-100

A-84

D-84

O-92

TT-5

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*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR THE REPLACEMENT OF THE LOW PRESSURE ACTUATORS FOR THE INTAKE VALVE ON CERTAIN C11 AND C13 TRUCK ENGINES
1130		PS51276

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NOTE:

This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS51276" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.

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NOTE:

The information supplied in this service letter may not be valid after the termination date of this program. Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.

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NOTE:	This Revised Service Letter replaces the 16Mar2007 Service Letter. Changes have been made to the Parts Needed.

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TERMINATION DATE

31Mar2008

PROBLEM

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"VVA Not Responding" faults are ocurring on certain C11 and C13 Truck Engines. This failure results in the check engine lamp being illuminated and possible engine derate.

AFFECTED PRODUCT

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Model	Identification Number
C11	KCA08296-09406, 9408-10340, 10342-11749, 11751-12485, 12493-12496, 12498-12500, 12506-12539, 12545-12711
C13	JAM00116-00169 KCB51434-51675, 53394-56726, 56728-57477, 57479-57502, 57504-57561, 57563-58782, 58784-58794, 58796-60010, 60012, 60014-60032, 60034-60080, 60082-60100, 60102-60119, 60121-60126, 60128-60166, 60168-63714, 63716-63803, 63806-63807, 63809, 63811, 63813-63814, 63816, 63818, 63820, 63822-63823, 63825-63826, 63828, 63830-63832, 63834, 63836, 63840-63843, 63845, 63847, 63850-63851, 63853-63854, 63856-63857, 63860-63863, 63865-63866, 63868-63870, 63872, 63874-63877, 63880-63882, 63884-63885, 63887-63888, 63890-63891, 63893-63894, 63896, 63898, 63900-63901, 63904-63907, 63909, 63911-63912, 63914-63915, 63917-63920, 63922, 63924, 63926-63927, 63929, 63931, 63935, 63938-63946, 63949-63950, 63953-63954, 63956, 63958-63959, 63961-63962, 63964-63965, 63967-63968, 63970-63974, 63976-63978, 63981, 63983, 63985-63986, 63989-63991, 63993-63995, 63997, 63999, 64001-64002, 64004-64005, 64007, 64009-64011, 64013-64018, 64020-64021, 64023-64024, 64026, 64028, 64030, 64033-64034, 64036-64037, 64040-64042, 64044, 64046-64047, 64049-64050, 64053-64054, 64057-64059, 64062-64063, 64065, 64067-64069, 64071-64072, 64074-64075, 64077-64079, 64081-64083, 64085, 64087, 64090-64095, 64097, 64100, 64102, 64104, 64107, 64110-64112, 64115, 64117-65087, 65089-65718, 65720-65779, 65781-65791, 65793-65850, 65852-66588, 66590-66671, 66673-66745, 66747-66760, 66762-67324, 67326-73437, 73439-73458, 73460-73531, 73533-73540, 73542-73551, 73553-73666, 73674, 73678, 73682, 73685, 73687-73775, 73779-73780, 73782, 73784, 73787-73790, 73792-73794, 73796-73802, 73805, 73809-74183, 74187-74188, 74191-74194, 74197-74384, 74386-74512, 74515-74602, 74604-74661, 74664-74725, 74730, 74732-74734, 74736-74738, 74740-76410, 76414-76443, 76445-76446, 76449, 76452-76461, 76463-76508, 76510, 76513, 76516, 76518-76521, 76524, 76526-76529, 76531-76535, 76538-76555, 76558, 76560-76593, 76595-76599, 76601-76609, 76612, 76614-76615, 76617, 76619-76620, 76623-76624, 76626, 76629-76651, 76654-76662, 76664-76666, 76668-76671, 76673-76674, 76678, 76680, 76682-76683, 76686-76687, 76689, 76693-76694, 76698-76699, 76701-76703, 76706-76707, 76712-77476, 77478, 77480, 77482-77484, 77486-77498, 77500-77503, 77505-77515, 77517-77520, 77522, 77524-77527, 77529-77531, 77533-77545, 77547-77550, 77552-77553, 77555-77556, 77558-77578, 77580-84189, 84198-84199, 84206-86438, 86441-89063, 89065-89072, 89074-89979, 89981-89998, 90000-90019, 90021-90073, 90076, 90080-90081, 90084-90085, 90087, 90089, 90091-90093, 90095, 90098-90099, 90102, 90104-90105, 90107-90114, 90116-90117, 90120-90137, 90139-90164, 90166-90205, 90209-90224, 90227-90231, 90234, 90239-90240, 90244, 90247, 90249-90252, 90262-90303, 90305-90361, 90364-90370, 90372-90437, 90441, 90444-90475, 90477-90622, 90624-90629, 90631-90687, 90689-90716, 90718-90719, 90722-90750, 90752-90756, 90763, 90767-90778, 90780-90793, 90795-90816, 90820-90860, 90863-90950, 90952, 90954-90972, 90975-90978, 90980-91024, 91028-91041, 91045-91058, 91060-91089, 91091-91124, 91133-91138, 91140-91761, 91763-91765, 91767, 91770-91771, 91774-91775, 91777-91783, 91785, 91787-91797, 91799-91801, 91805, 91807-91809, 91811-91815, 91817, 91819-91821, 91823, 91826, 91828, 91830, 91834-91843, 91846-91849, 91851, 91855, 91857-91858, 91861, 91864, 91866-91867, 91869-91870, 91872-91874, 91877-91879, 91881, 91883-91887, 91889-91952, 91954-91980, 91982-91997, 91999-92000, 92002, 92004-92011, 92013-92018, 92020-93137

PARTS NEEDED

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Qty	Part Number	Description
3	10R7302	KIT-ACTUATOR
In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 3% of dealership population. This is an inital order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.

ACTION REQUIRED

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This service letter will address the replacement of ALL 1 piece Low Pressure Actuators (LPA) on the engine. The ECM must show "VVA Not Responding" faults. This will be required in order to apply this service letter. The active or logged faults codes are as follows: 285-07, 286-07, 287-07, 288-07, 289-07, or 290-07. A warranty download to SMIS is required. The following Rework procedure will explain how to install the 2-piece LPAs. You are to ONLY replace the 1 piece LPAs on the engine. The kit comes with (2) 2 piece LPAs. Check your engine before ordering. You may have to order 1 or up to 3 kits depending on how many 1 piece LPAs are on the engine. Image 1 shows the difference between the 1 piece LPA and 2-piece LPA.

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Image1

SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
0-300000 miles, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 2.0-hour job

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PARTS DISPOSITION

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Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

Rework Procedure

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Tool List
1. 247-5377 torque wrench (compact T-handle) capable of 2.3+/-0.2 N-m (20.4+/-1.8 inch-pound) for 3 mm valve screw removal/installation (247-5377)
2. 10 IP Torx plus driver
3. 6 IP Torx plus or T6 Torx for 2 mm carrier screw removal.
4. 222-3124 Electrical Component Cleaner

Potential Source of Tools: (Wiha Quality Tools, http://www.wihatools.com)
1. Wiha torque-vario-s 7 piece kit number 28598. This includes a 10-IP driver bit and tool for setting the torque to 20 in-lbs. Replacement torque driver number is 285-06.
2. Wiha 6-IP and 10-IP driver bit number 28572 and 28576. This works with the torque-vario-s driver.

Kit contains:
(8) 221-9939 Screw M3x0.5
(2) 221-9895 Actuator Gp

(Images are for illustration purposes. The work is intended to be done on engine without removing the entire actuator housing.)

1. Remove valve cover from engine.

2. Remove old valves from the Actuator, image 1.1.1 and 1.1.2. Do not un-bolt VVA housings from cylinder head. Unplug solenoid valve from wire harness, image 1.6.1. Remove 4 screws (M3) using 10 IP Torx plus insert tool. Remove valve from assembly. Send old valve back using claims return. Discard old M3 screws.

Image1.1.1

Image1.1.2

3. Clean valve mounting surface using Electrical Component Cleaner, image 1.2.1. Surfaces must be kept clean.

Image1.2.1

4. Install new M3 screws into valve from kit, image 1.3.1. There are four screws per valve. Check to make certain screws drop down freely and have no binding. If binding is noticed, then loosen the two M2 carrier screws ? turn using the 6 IP torx plus tool and do not retighten.

Image1.3.1

5. Install each new valve, image 1.4.1. and 1.4.2 Orient the connector and screw holes. The valve must be oriented as shown in figures by rotating the valve assembly such that the black wire harness connector appears as the figures and the screw holes line up with tapped holes in the housing. Snug the M3 screws down in a cross pattern 1-2-3-4, image 1.4.3. Use 10 IP Torx plus tool. Note: All the M3 screws need to be snugged down prior to torquing.

Image1.4.1

Image1.4.2

6. Final torque of each valve. Torque the four M3 screws to 2.3 +/- 0.2 N-m (20.4+/-1.8 inch-pound) in a cross pattern 1-2-3-4, image 1.4.3. Note: Failure to insure that screws do not bind and/or improper torquing process can cause actuator not responding faults.

7. Remove two M2 carrier screws per valve, image 1.5.1. Use the 6 IP Torx plus or T-6 Torx tool. Note: Failure to remove these screws may cause them to become loose during engine operation and result in damage. The M2 carrier screws need to be screwed in to the old valves being sent back through the claims process.

Image1.5.1

8. Plug wire harness into both valve connectors, image 1.6.1. Note: The bail clips that hold the wire harness to the valve must be fully latched.

Image1.6.1

9. Repeat steps 2 through 8 for remaining cylinders.

10. Re-assemble engine.

11. Run Intake Valve Actuator Response Test SMCS - 5479-038-IL to confirm VVA operation. Perform the Road Test, see below.

Road Test Highlights
If a road test is performed the road test must be performed under the following conditions, loaded conditions with at least 75 percent of the rated fuel rate for more than 30 seconds.
If the intake valve actuator failed the "Intake Valve Actuator Test", verify that the repair eliminates the problem by performing another "Intake Valve Actuator Test". If the intake valve actuator did not fail the "Intake Valve Actuator Test", perform a road test. Some problems will only occur when the engine is under a load.