Replacing Low Pressure Actuator Valves{1130} Caterpillar

Engine:

C11 (S/N: KCA1-UP)

C13 (S/N: KCB1-UP; LEE1-UP; JAM1-UP; S3C1-UP)

C15 (S/N: BXS1-UP; MXS1-UP; NXS1-UP; SDP1-UP; B5R1-UP)

Introduction

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

The procedure that follows is designed to provide a more timely and a more economical repair when the troubleshooting procedure calls for the repair of the intake valve actuator. Replace both actuator valves on the variable valve actuator housing that has the associated fault code. Intake Valve Actuator Not Responding faults can be caused by other system problems. The system problems should be repaired before troubleshooting Intake Valve Actuator Not Responding faults. If there are other fault codes present, refer to the correct procedure in the Troubleshooting Guide.

Tool List

• 247-5377

• 10-IP Torx plus driver

• 6-IP Torx plus or T6 Torx

• 222-3124

• Wiha torque varios kit: 28598

• Wiha 6-IP driver: 28572

• Wiha 10-IP driver: 28576

Actuator Kit

Procedure

1. Remove the valve cover from the engine.

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Illustration 1	g01413849

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Illustration 2	g01413857

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Illustration 3	g01413859
(1) Wire harness connector

2. Remove the old valves from the actuator. Refer to Illustrations 1 and 2. Do not remove the housing for the variable valve actuator from the cylinder head. Unplug the solenoid valve from the wire harness. Refer to Illustration 3. Remove the four screws. Remove the valve assembly.

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Illustration 4	g01413865

3. Clean the valve mounting surface with electrical component cleaner. Refer to Illustration 4.

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Illustration 5	g01413881

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Illustration 6	g01414713
C11 and C13 Use 221-9939 Screw

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Illustration 7	g01414709
S/N:BXS Use 221-9939 Screw

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Illustration 8	g01414746
Intake valve actuator for S/N:BXS (2) Stop plate

Note: Ensure that stop plate (2 ) is orientated correctly. The groove in stop plate (2) must be facing toward the valve.

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Illustration 9	g01414715
C15 except for S/N:BXS Use 220-0684 Screw

4. Install new screws into the valve. There are four screws per valve. Refer to Illustrations 5 through 9. Ensure that the screws can be inserted without binding. If binding does occur, loosen the two carrier screws.

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Illustration 10	g01413891
(3) Orientation of the valves

5. Install each new valve. Orient the valves and the holes for the screws. Refer to Illustration 10. The holes for the screws must align with the tapped holes in the housing. Secure the screws. The screws must be secured in a cross pattern. Refer to Illustration 11.

   Note: The correct screws must be used. Disgard the other set of screws. Ensure that the orientation of the valves is same orientation as on the valves.

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Illustration 11	g01413906
Tightening sequence

6. Torque the screws to 2.3 ± 0.2 N·m (20.36 ± 1.77 lb in). The screws must be secured in a cross pattern. Refer to Illustration 11.

   Note: Failure to ensure that the screws are torqued properly can lead to failures.

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Illustration 12	g01414434
(4) Carrier screws

7. Remove the two carrier screws. Refer to Illustration 12.

   Note: Failure to remove the screws may cause the screws to become loose during engine operation. Loose screws can cause damage to the engine.

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Illustration 13	g01413859
(1) Wire harness connector

8. Plug the wire harness into both valve connectors. Refer to Illustration 3.

   Note: The bail clips that hold the wire harness to the valve must be fully latched.

9. Repeat Steps 2 through 8 for the remaining cylinders.

10. Reassembly the engine.

11. Run the intake valve actuator response test to confirm the operation of the variable valve actuator.

Road Test

Perform a road test under the following conditions.

• Must have a load

• 75% 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 eliminated the problem. Perform another "Intake Valve Actuator - Test". If the intake valve actuator did not fail the "Intake Valve Actuator - Test", perform a road test.