PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE VVA OIL SUPPLY LINE ON CERTAIN C15 TRUCK ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE VVA OIL SUPPLY LINE ON CERTAIN C15 TRUCK ENGINES

Usage:

REBE5040-01

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18Jun2009

(Revised 11Nov2009)

U-224

A-192

D-192

O-198

TT-33

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE VVA OIL SUPPLY LINE ON CERTAIN C15 TRUCK ENGINES
1307 1105 1130		PI10761

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10761" as the Part Number and "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description Code.
Exception: If the repair is done after failure, use "PI10761" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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NOTE:	This Revised Service Letter replaces the 18Jun2009 Service Letter. Changes have been made to Group 1 of the Affected Product.

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PROBLEM

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The VVA oil line may wear and cause an oil leak, which may result in a fire hazard.

This Product Improvement Program is a Safety Recall in accordance
with the US National Traffic and Motor Vehicle Safety Act and the
Canadian Motor Vehicle Safety Act. It is a violation of US Federal law
for a dealer to deliver a new motor vehicle or new or used engine covered
by this Safety PIP until the PIP has been completed.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
DV-C15	KRA00100-00103, 105-112, 114-333, 359-718, 744-1932, 1934-2362, 2364-3053, 3055-3084, 3086-3087, 3089, 3091-3095, 3097-3124, 3126-3128, 3130-3139, 3141-3147, 3149, 3151-3153, 3155, 3157-3158, 3165-3171, 3173-3178, 3180-3181, 3183-3185, 3187-3189, 3191, 3193-3194, 3196, 3199, 3202, 3204-3205, 3211-3214, 3223, 3230, 3234, 3242, 3252, 3257-3258, 3270-3272, 3278-3279, 3291, 3293-3295, 3301, 3304, 3313-3315, 3319-3321, 3327, 3330-3333, 3336-3337, 3339-3345, 3348-3349, 3352, 3354, 3357-3358, 3360-3362, 3364-3365, 3367-3383, 3385-3387, 3390-3391, 3393-3420, 3422-3424, 3426-3444, 3446-3448, 3450-3465, 3467-3485, 3487-3507, 3509-3520, 3523-3525, 3527-3545, 3547-3560, 3562-3564, 3567-3569, 3572-3574, 3576, 3578, 3580, 3582-3586, 3589, 3591-3592, 3595, 3597-3598, 3601, 3607, 3610-3614, 3617-3632, 3635-3639, 3654, 3656-3657, 3660-3662, 3668, 3672, 3675-3676, 3678, 3680-3688, 3693-3695, 3702-3704, 3706-3707, 3710-3714, 3716, 3720-3721, 3724, 3726-3730, 3733-3743, 3745-3752, 3760, 3762-3763, 3768-3769, 3772-3773, 3775, 3780

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*****Group 2*****
C15	JEP00001-00060, 63-168

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*****Group 3*****
DV-C15	TRB00001-00008

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	0S1594	BOLT
1	5M2894	WASHER-HARD
1	7G1239	SPACER
1	8M0547	ELBOW
2	0336027	SEAL-O-RING
1	3401286	HOSE AS-SUPPLY
1	3441950	CLIP-HALF SLOT
1	3441951	CLIP-HALF TAB
1	3493552	VALVE-CHECK
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
*****Group 2*****
1	0S1591	BOLT
1	2P1292	CONNECTOR-PORT
3	0336027	SEAL-O-RING
1	1124387	ELBOW
1	2869133	VALVE AS-CHECK-A
1	3401286	HOSE AS-SUPPLY
1	3441950	CLIP-HALF SLOT
1	3441951	CLIP-HALF TAB
1	3460344	SPACER
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
*****Group 3*****
1	0S1591	BOLT
2	0336027	SEAL-O-RING
1	1124387	ELBOW
1	2869133	VALVE AS-CHECK-A
1	3401286	HOSE AS-SUPPLY
1	3441950	CLIP-HALF SLOT
1	3441951	CLIP-HALF TAB
1	3460344	SPACER
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% of dealership population. This is an initial 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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Replace the 235-1995 oil line with the new 340-1286 oil line. Refer to the attached Rework Procedure.

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OWNER NOTIFICATION

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U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 5.0-hour job for Group 1

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 5.0-hour job for Group 2

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 2.0-hour job for Group 3

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PARTS DISPOSITION

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

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

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COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

IMPORTANT: SAFETY NOTICE

SAFETY ? RECALL - PROGRAM FOR REPLACING THE VVA OIL SUPPLY LINE

MODELS INVOLVED - CERTAIN C15 TRUCK ENGINES

Dear Caterpillar Product Owner:
This notice is sent to you in accordance with the requirements of the US National Traffic and Motor Vehicle Safety Act. This notice is also in accordance with the requirements of the Canadian Motor Vehicle Safety Act. Caterpillar has decided that a defect, which relates to motor vehicle safety, exists in trucks equipped with certain Caterpillar C15 engines.

The VVA oil line may wear and cause an oil leak, which may result in a fire hazard. The remedy will replace the VVA line assembly. You will not be charged for the service performed.

If you are a lessor of these vehicles, you must forward this letter to your lessee within ten days.

If you have had your vehicle repaired for this condition prior to receipt of this notice and incurred any costs, you may be eligible for reimbursement. Please contact Caterpillar at this toll free number (800) 447-4986.

If you no longer own the truck with this engine, please contact Caterpillar at this toll free number (800) 447-4986.

Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

If the dealer is unable to have the inspection and repair made, please contact:

Caterpillar Inc.
Peoria, IL 61629-2490
Attn: Americas Distribution Services Division
Truck Engine Call Center
Telephone: (800) 447-4986

If you are unable to have the inspection and repair made within 60 days or without charge, you may submit a complaint to:

In the U.S.
Administrator
National Highway Traffic Safety Administration
1200 New Jersey Avenue, S.E.
Washington, D.C. 20590
Telephone: 1-888-327-4236 (TTY:1-800-424-9153)or go to http://www.safercar.gov

In Canada
Transport Canada
Road Safety and Motor Vehicle Regulation
Ottawa, Ontario KIA 0N5
Telephone: (613) 993-9851

Please refer the dealer to their Service Letter dated 18Jun2009 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed for your added safety and satisfaction.

Please refer the dealer to their Service Letter dated 18Jun2009 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed for your added safety and satisfaction.

Caterpillar Inc.

Identification #(s)

Attached to 18Jun2009 Service Letter

Rework Procedure

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Group Number 1

Disassembly:

1. Remove the bolt (9) from the lifting eye. Do not reuse. Refer to Image1.1.1

Image1.1.1

2. Remove the following items from the engine: 235-1995 Hose Assembly (4), 202-2762 Clip (3), 202-2762 Clip (5), 232-4937 Check Valve (8), 0S-0509 Bolt (6), 9X-6458 Hard Washer (7). Do not reuse these parts. Refer to Image1.2.1.

3. Remove 6K-3607 Connector (2) and 033-6027 O-ring (1) from the valve cover base. Retain the connector for reuse, the connector will be reinstalled with the new 340-1286 Hose As. Do not reuse the 033-6027 O-ring. Refer to Image1.2.1.

Image1.2.1

Refer to Image1.3.1 for Assembly:

Assembly:

4. Install the 6K-3607 Connector (8) that was removed from the back of the cylinder head in Step 3 and a new 033-6027 O-ring seal (9) into the 237-2849 Tee (10) currently installed in the engine.

5. Install a new 349-3552 Check Valve Assembly (2) and 033-6027 O-ring (1) into the valve cover base.

6. Install a new 8M-0547 Elbow (3) onto the check valve assembly (2).

7. Attach the new 344-1950 and 344-1951 Clips (6) to the 340-1286 Hose Assembly (7) with the curved half of the clip toward the engine. Tie the loose ends of the clips in order to hold the clips together during the assembly to the engine.

8. Attach the hose assembly to the lower connector (8) and then to the elbow (3) from the check valve connected to the back of the cylinder head (2). Hand tighten both ends of the hose assembly.

9. Attach the hose clips (6) and the 7G-1239 Spacer (4) with the 0S-1594 Bolt (5) and 5M-2894 Hard Washer.

NOTE: Insert the hard washer between the bolt head and the clips, and the spacer between the hose clips and the back of the cylinder head.

10. Tighten both ends of the hose assembly that was installed in Step 8. Tighten the fitting at elbow (3) first.

Image1.3.1

Group Number 2

Disassembly:

1. Remove the bolt (9) from the lifting eye. Do not reuse. Refer to Image2.1.1

Image2.1.1

2. Remove the following items from the engine: 235-1995 Hose Assembly (4), 202-2762 Clip (3), 202-2762 Clip (5), 232-4937 Check Valve (8), 0S-0509 Bolt (6), 9X-6458 Hard Washer (7). Do not reuse these parts. Refer to Image2.2.1.

3. Remove 6K-3607 Connector (2) and 033-6027 O-ring (1) from the valve cover base. Retain the connector for reuse, the connector will be reinstalled with the new 340-1286 Hose As. Do not reuse the 033-6027 O-ring. Refer to Image2.2.1.

Image2.2.1

4. Refer to Image2.3.1. Inspect the fitting installed in the engine.
- If the 2P-1292 Fitting is installed, proceed to Step 5.
- If the 9M-4584 Fitting is installed, remove the 9M-4584 Fitting and replace it with the new 2P-1292 Fitting and new 033-6027 O-ring seal.

Image2.3.1

Refer to Image2.4.1 for Assembly

Assembly:

5. Install the 6K-3607 Connector (8) that was removed from the back of the cylinder head in Step 3 and a new 033-6027 O-ring seal (9) into the 237-2849 Tee (10) installed in the engine.

6. Install a new 286-9133 Check Valve Assembly (2) and 033-6027 O-ring (1) into the valve cover base.

7. Install a new 112-4387 Elbow (3) onto the check valve assembly (2).

8. Attach the new 344-1950 and 344-1951 Clips (6) to the 340-1286 Hose Assembly (7) with the curved half of the clip toward the engine. Tie the loose ends of the clips in order to hold the clips together during the assembly to the engine.

9. Attach the hose assembly to the lower connector (8) and then to the elbow (3) from the check valve connected to the back of the cylinder head (2). Hand tighten both ends of the hose assembly.

10. Attach the hose clips (6) and the 346-0344 Spacer (4) with the 0S-1591 Bolt (5).
NOTE: Insert the spacer between the hose clips and the back of the cylinder head.

11. Tighten both ends of the hose assembly. Tighten the fitting at elbow (3) first.

Image2.4.1

12. Inspect the clearance between the VVA elbow and the CAC pipe. Refer to Image2.5.1.
- If the clearance is less than 38mm (1.5 in.), the CAC pipe must be loosened and readjusted to a minimum of 38mm (1.5 in.) clearance.
- If the clearance is 38mm (1.5 in.) or more, no further adjustment is necessary.

Image2.5.1

Group Number 3

Disassembly:

1. Remove the bolt (9) from the lifting eye. Do not reuse. Refer to Image3.1.1

Image3.1.1

2. Remove the following items from the engine: 235-1995 Hose Assembly (4), 202-2762 Clip (3), 202-2762 Clip (5), 232-4937 Check Valve (8), 0S-0509 Bolt (6), 9X-6458 Hard Washer (7). Do not reuse these parts. Refer to Image3.2.1.

3. Remove 6K-3607 Connector (2) and 033-6027 O-ring (1) from the valve cover base. Retain the connector for reuse, the connector will be reinstalled with the new 340-1286 Hose As. Do not reuse the 033-6027 O-ring. Refer to Image3.2.1.

Image3.2.1

Refer to Image3.3.1 for Assembly

Assembly:

4. Install the 6K-3607 Connector (8) that was removed from the back of the cylinder head in Step 3 and a new 033-6027 O-ring seal (9) into the 237-2849 Tee (10) installed in the engine.

5. Install a new 286-9133 Check Valve Assembly (2) and 033-6027 O-ring (1) into the valve cover base.

6. Install a new 112-4387 Elbow (3) onto the check valve assembly (2).

7. Attach the new 344-1950 and 344-1951 Clips (6) to the 340-1286 Hose Assembly (7) with the curved half of the clip toward the engine. Tie the loose ends of the clips in order to hold the clips together during the assembly to the engine.

8. Attach the hose assembly to the lower connector (8) and then to the elbow (3) from the check valve connected to the back of the cylinder head (2). Hand tighten both ends of the hose assembly.

9. Attach the hose clips (6) and the 346-0344 Spacer (4) with the 0S-1591 Bolt (5).
NOTE: Insert the spacer between the hose clips and the back of the cylinder head.

10. Tighten both ends of the hose assembly. Tighten the fitting at elbow (3) first.