- Engine
- G3508 (S/N: 9TG1-UP; WPM1-UP; WPN1-UP; DLR1-UP)
- G3508B (S/N: JB31-UP; N8C1-UP; RBK1-UP)
- G3508J (S/N: N8W1-UP)
- G3512 (S/N: 7NJ1-UP; E2N1-UP; E2P1-UP; WPP1-UP; WPR1-UP; E2S1-UP; GNS1-UP; E2T1-UP; E2X1-UP)
- G3512B (S/N: JHH1-UP; N2S1-UP; JBW1-UP)
- G3512E (S/N: NWC1-UP; GFM1-UP; SSR1-UP; NGS1-UP; SST1-UP)
- G3516 (S/N: AL71-UP; ZBA1-UP; L6E1-UP; L6G1-UP; 4EK1-UP; WPS1-UP; CSZ1-UP)
- G3516B (S/N: CW51-UP; N6E1-UP; JEF1-UP)
- G3516C (S/N: GG31-UP; NG61-UP; GSB1-UP; TJB1-UP; GZC1-UP; TJC1-UP; F6D1-UP; NWD1-UP; F6E1-UP; G7E1-UP; NWE1-UP; F6F1-UP; NWF1-UP; F6M1-UP; N6R1-UP; GZZ1-UP)
- G3516E (S/N: F6G1-UP; NWG1-UP; GAS1-UP; SLY1-UP)
- G3516J (S/N: N6W1-UP)
- G3520 (S/N: HET1-UP)
- G3520B (S/N: GLF1-UP; GET1-UP)
- G3520C (S/N: GZA1-UP; HEA1-UP; GZB1-UP; HEB1-UP; MAD1-UP; GZJ1-UP; GZK1-UP; GZL1-UP; GZM1-UP; GZN1-UP; B9P1-UP; RLP1-UP; LGS1-UP; HAT1-UP; CWW1-UP; CWY1-UP)
- G3520E (S/N: GZE1-UP; GZG1-UP; GZH1-UP; HAL1-UP; SXY1-UP)
- G3520J (S/N: N221-UP; N241-UP)
- G3508B (S/N: JB31-UP; N8C1-UP; RBK1-UP)
- Petroleum Engine
- G3520B PETROLEUM (S/N: TPC1-UP)
- Power Module
- PMG3516 (S/N: GJK1-UP; JKK1-UP)
Introduction
Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.
This Special Instruction describes the rework procedure for replacing the outboard bearing for the Integrated Throttle Body (ITB).
Safety Section
Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility. |
Required Parts
Table 1 contains the parts for the 555-1602 Bearing Kit. The bearing kit is serviceable as a whole and not by individual parts.
Part Description | Quantity |
---|---|
Pointer | 1 |
Pointer Screw | 1 |
Spring Seat | 1 |
Spring | 1 |
Seal Assembly | 1 |
Cap O-ring | 1 |
Cap | 1 |
Cap Screw | 2 |
Bearing | 1 |
Required Tools
Tool Description | Quantity |
---|---|
Loctite® 243 Blue Threadlocker | 1 |
Loctite® Silver Grade Anti-Seize Stick | 1 |
Krytox™Lubricants | 1 |
Kano Laboratories® Kroil Penetrating Oil | 1 |
Hooked Pick | 1 |
Allen Key |
1 |
Phillips Screwdriver | 1 |
Loctite® 243 Blue Threadlocker
https://www.henkel-adhesives.com/us/en/product/threadlockers/loctite_243.htmlLoctite® Silver Grade Anti-Seize Stick
https://www.henkel-adhesives.com/us/en/product/anti-seize-lubricants/loctite_silver_gradeanti-seizestickautomotiveaftermarketonly.htmlKrytox™Lubricants
https://www.chemours.com/Lubricants/en_US/index.htmlKano Laboratories® Kroil Penetrating Oil
http://www.kanolabs.com/penLub.htmlTable 3 contains the parts for the 554-5061 Tool As-Removal. The tool removal assembly is serviceable as a whole and not by individual parts.
Tool Description | Quantity |
---|---|
Collet | 1 |
Collet Sleeve | 1 |
Spring Pin | 1 |
Collet Handle | 1 |
Washer | 1 |
Jam Ring | 1 |
Verification Procedure
Before replacing the outboard bearing, it is important to be sure that the bearing needs replaced. To determine the health of the bearing, follow the steps below.
- Power-down the ITB.
- Move the valve by repositioning the pointer by hand.
Note: A good bearing will allow the valve to move smoothly and easily.
- If the valve is difficult to move, or the valve does not move at all, then the bearing has likely failed.
Overview
Illustration 1 | g06322742 |
(A) Pointer
(B) Pointer Screw (C) Spring Seat (D) Spring (E) Seal Assembly (F) Cap O-ring (G) Cap (H) Bearing (J) Cap Screw |
Illustration 1 shows an example of the parts that will be replaced.
Removal Procedure
- Close the throttle valve by hand and mark the location of pointer (A) on ITB housing (K).
- Unscrew pointer screw (B).
- Remove pointer (A).
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Illustration 3 g06324144 (G) Cap
(J) Cap Screws
(T1) Allen Key4 mm (5/32 inch) - Using allen key (T1), unscrew cap screws (J) together evenly from cap (G) to prevent damage to the ITB housing.
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Illustration 4 g06323354 (C) Spring Seat
(D) Spring
(E) Seal Assembly
(F) Cap O-ring
(G) Cap - Remove cap (G), seal assembly (E), and cap o-ring (F).
- Remove spring seat (C), and spring (D).
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Illustration 5 g06323357 Example of shaft and sealing surfaces - Inspect the shaft and housing sealing surfaces.
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Illustration 6 g06323359 (L) Bearing Seal
(T2) Hooked Pick - Remove bearing seal (L) from the old bearing with a small screwdriver or hooked pick (T2).
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Illustration 7 g06323381 Example of bearing without seal
(M) Bearing
(T3) Kano Laboratories® Kroil Penetrating Oil - Soak bearing (M) and the surrounding area with Kano Laboratories® Kroil Penetrating Oil (T3) or equivalent to help remove excess particles and help loosen the bearing from the shaft.
Note: Let the solution sit for a minimum of 5 minutes.
Show/hide tableIllustration 8 g06323383 (T4) 554-5061 Tool As-RemovalShow/hide tableIllustration 9 g06322934 Exploded view of 554-5061 Tool As-Removal
(T5) Collet
(T6) Collet Sleeve
(T7) Spring Pin
(T8) Collet Handle
(T9) Washer
(T10) Jam RingShow/hide tableIllustration 10 g06322950 (M) Bearing Inner Race Lip
(M) Bearing Inner Race Groove
(T5) Collet Lip - Place the opening of the tool over bearing inner race lip (M). Collet lip (T2) should be centered over bearing inner race groove (M).
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Illustration 11 g06323387 (T6) Collet Sleeve
(T8) Collet Handle - While using one hand to hold collet handle (T8) securely, use the other hand to tighten collet sleeve (T6). Turn the collet sleeve clockwise until resistance is felt. Once resistance is felt, stop tightening the collet sleeve. The tool should be securely engaged to the bearing.
Note: The collet grips the bearing by hooking into the bearing inner race lip. This tool does not work by resistance/friction means. To prevent damage to the bearing remover tool, specifically the collet, do not over-tighten the sleeve.
- Slide washer (T9) over the tool until the washer sits against the valve body.
- Screw jam ring (T10) onto collet sleeve (T6) until the jam ring contacts the washer.
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Illustration 12 g06323389 (T6) Collet Sleeve
(T10) Jam Ring - Hold collet sleeve (T6) and tighten jam ring (T10) by hand approximately 5 turns. At this point the old bearing should be free enough from the shaft to be removed by hand.
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Illustration 13 g06323391 (M) Bearing
(T5) Collet
(T6) Collet Sleeve - Remove the 554-5061 Tool As-Removal with bearing (M) from the ITB housing. Then, remove the old bearing from 554-5061 by loosening collet (T5) from collet sleeve (T6).
- Ensure that all the bearing bore surfaces and parts are clean before proceeding.
Illustration 2 | g06323349 |
Example of pointer location (A) Pointer (B) Pointer Screw (K) ITB Housing |
Installation Procedure
- Wipe down the inside bore with a clean, dry cloth.
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Illustration 15 g06323398 Example of lubricated ITB bearing bore
(T11) Loctite ® Silver Grade Anti-Seize Stick - Apply a light coating of Loctite ® Silver Grade Anti-Seize Stick (T11) into the bearing bore.
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Illustration 16 g06323342 Example of new bearing in ITB housing - Install the new bearing in the housing.
Note: The bearing should slide in place by hand. Do not use impact devices to install the bearing.
Note: Make sure that the bearing is fully seated on the valve shaft.
Show/hide tableIllustration 17 g06323405 (3) ITB Shaft Journal
(4) Cap O-ring
(5) Seal Assembly - Apply a light coating of Krytox™RFE PFPE Lubricant to shaft journal (3), cap O-ring (4), and seal assembly (5).
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Illustration 18 g06323407 (6) Spring Seat
(7) Spring - Place spring (7) in the housing against the bearing.
- Place spring seat (6) in the housing against the spring.
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Illustration 19 g06323410 Example of cap screws with Loctite ® 243 Blue Threadlocker applied
(8) Cap Screws - Applying one drop of Loctite ® 243 Blue Threadlocker on the threads of the two cap screws (8).
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Illustration 20 g06323413 (8) Cap Screws
(9) Cap Assembly - Place the new cap assembly over the spring and washer and compress the assembly into the housing.
- Thread the new screws into the cap/ housing, alternating between screws to walk the cap down into the housing.
- Torque to
3.8 ± -.2 N·m (34 ± -2 lb in) .
Show/hide tableIllustration 21 g06323416 (10) Pointer Screw
(11) Pointer
(T12) Loctite ® 243 Blue Threadlocker - Place pointer (11) on pointer screw (10) and apply one drop of Loctite ® 243 Blue Threadlocker (T12) on the screw threads.
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Illustration 22 g06323417 (9) Cap Assembly
(10) Pointer Screw
(11) Pointer - Close the throttle valve by hand.
- Place pointer (11) on cap assembly (9), and align the pointer with the mark made on the ITB housing.
- Tighten the pointer screw to
3.5 ± 4.3 N·m (31 ± 38 lb in) .
Show/hide tableIllustration 23 g06323418 Example of reassembled Integrated Throttle Body - After reassembly, to verify that no leakages are present, pressurize the system. Then, using a soap/water solution check for leaks around the cap/housing and cap/shaft interfaces.
- Pressurize the system with XX psi.
- Use a soap/water solution to check for leaks around all the ITB components.
Illustration 14 | g06323394 |
Example of ITB housing with the bearing removed |