PISTON 5138364 - Caterpillar

This is a 2.0-hour job
This Service Letter will allow 0.7 hours for inspection time on engines that are determined to already have the two piece LPA's installed. This Service Letter does not allow for the replacement of 2 piece LPA's
PARTS DISPOSITION
Return all parts to:
Engineering Parts Return Area
CATERPILLAR_INC.,__BUILDING_DD,_DOCK_8__ATTN: Joshua Evans
ROUTE_29_&_OLD_GALENA_ROAD
MOSSVILLE, ILLINOIS_ 61552
Rework Procedure
Tool List
1. 247-5377 torque screwdriver (compact T-handle) capable of 2.3 +/- 0.2 N-m (20.4 +/- 1.8 pound inches) for 3 mm valve screw removal/installation
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.
Actuator Kit contains:
(8) 221-9939 Screw M3 x 0.5
(2) 221-9895 Actuator Gp
(Images are for illustration purposes. The work is intended to be completed with actuator housings remaining installed on the engine.)
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 removed one piece LPA valves back using claims return. Do not reuse the 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 pound inches) in a cross pattern 1-2-3-4, image 1.4.2.
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 harnesses into both valve connectors, image 1.6.1.
Note: