2004/02/01 Caterpillar

Engine:

C7 (S/N: KAL1-15277)

During installation of the smart wastegate solenoid, improper clearance between the air inlet cover and the wastegate solenoid may contribute to damaged O-ring seals during assembly. Damage to the O-ring seals will result in leakage around the solenoid valve assembly. This leakage may result in the generation of 102-01 Low Boost Pressure Event Code by the engine's Electronic Control Module.

The location of the interference may be seen in Illustration 1.

Illustration 1	g01051376
Location of interference

Although the manufacturing process that has caused the interference has been corrected, corrective action on the engine may be necessary for the following effectivity: S/N:KAL1-15277

If the air inlet cover and the smart wastegate solenoid are in contact in the area that is shown, perform the "Repair Procedure" that is detailed in the section that follows.

Repair Procedure

If interference has been detected between the air inlet cover and the smart wastegate solenoid, perform the following procedure in order to correct the problem.

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Illustration 2	g01051908
(1) O-ring seals (2) Valve assembly (3) Solenoid assembly (4) Nut

1. Remove the smart wastegate solenoid from the engine.

   1. Remove nut (4) and the retaining washer from the rear of the wastegate control valve.

   2. Slide the solenoid assembly (3) from the valve assembly (2) .

   3. Remove valve assembly (2) from the air inlet cover.

2. Install a 7T-7679 Plug into the air inlet cover. This will prevent contamination from entering the engine during the grinding process.

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Illustration 3	g01051338
Area for removal of material

3. Use a pencil grinder to remove approximately 3 mm (0.12 inch) of material from the air inlet cover in the location that is shown in Illustration 3. Be sure that you remove enough material from this area to eliminate the interference between the two components.

4. Thoroughly clean the components after the grinding operation has been completed.

5. Remove the 7T-7679 Plug from the air inlet cover.

Note: During installation of the smart wastegate solenoid, ensure that the repair was successful. At the location that is indicated in Illustration 1, there should be no interference between the components.

6. Reinstall the smart wastegate solenoid onto the air inlet cover. Refer to Illustration 2.

   1. Install a new 232-7493 Seal Kit onto the solenoid valve. Lubricate the new O-ring seals (1) with 5P-3975 Rubber Lubricant .

   2. Ensure that solenoid assembly (3) has been removed from valve assembly (2). This must be done prior to installation of the valve assembly onto the air inlet cover. For information that relates to removing the solenoid assembly, refer to Step 1.

   3. Install valve assembly (2) into the air inlet cover and torque the assembly to the following value.

      Torque for valve assembly (2) ... 50 ± 5 N·m (36 ± 4 lb ft)

   4. Reinstall the solenoid assembly (3) onto the valve assembly (2). Install the retaining washer and nut (4). Torque the nut to the following value.

      Torque for nut (4) ... 13 ± 1.5 N·m (10 ± 1 lb ft)