System Operation Description:
“Intake Valve Actuator Test”
The “Intake Valve Actuator Test” can be used to troubleshoot mechanical problems with the intake valve actuators. When the test is active, the Caterpillar Electronic Technician (Cat ET) will disable the injectors for three cylinders. Cat ET will then turn on one of the intake valve actuators for one of the remaining cylinders. Cat ET monitors the fuel position in order to determine if the intake valve actuator is working properly. Once the test is complete, Cat ET will display “OK” or “Not OK” next to each cylinder number.
Test Step 1. Check the Engine Oil Level
A. Stop the engine. Allow the engine to cool.
B. Check the engine oil level.
Expected Result:
The engine oil level is OK.
Results:
• OK – The engine oil level is OK.
Repair: Verify that the dipstick is calibrated correctly. Refer to Operation and Maintenance Manual, “Engine Oil Level Gauge – Calibrate”.
Proceed to Test Step 3.
• Not OK – The engine oil level is low.
Repair: Verify that the dipstick is calibrated correctly. Refer to Operation and Maintenance Manual, “Engine Oil Level Gauge – Calibrate”.
Add engine oil to the proper level.
Proceed to Test Step 2.
Test Step 2. Check the Engine for Leaks
A. Visually check the engine for oil leaks.
Expected Result:
There are no visible oil leaks on the engine.
Results:
• OK – There are no visible oil leaks on the engine.
Repair: Operate the engine under the same conditions that caused the problem. Verify that the low oil level caused the problem.
STOP.
• Not OK – There is a detectable oil leak.
Repair: Determine the source of the oil leak.
Repair the leak.
Verify that the repair eliminates the problem.
STOP.
Test Step 3. Check the Engine Oil Pressure
A. Turn the key switch to the OFF position.
B. Connect the Caterpillar Electronic Technician (Cat ET) to the data link connector.
C. Start the engine and allow the engine to warm up to operating temperature.
D. Monitor the status for “Engine Oil Pressure” on Cat ET while the engine is operated throughout the rpm range. Also check the oil pressure gauge in the cab.
E. Verify that the oil pressure is above the trip point in Illustration 124 or Illustration 125.
F. Turn the key switch to the OFF position.
Expected Result:
The engine oil pressure is above the trip point.
Results:
• OK – The engine oil pressure is OK. Proceed to Test Step 4.
• Not OK – The engine oil pressure is low.
Repair: If there are any active diagnostic codes that are related to low oil pressure, refer to the appropriate topic in Troubleshooting, “Troubleshooting with a Diagnostic Code”.
If there are no diagnostic codes that are related to low oil pressure, refer to Testing and Adjusting, “Engine Oil Pressure – Test”.
STOP.
Test Step 4. Check for Diagnostic Codes
A. Turn the key switch to the “ON” position.
B. Check for the following logged diagnostic codes:
• 283-07 Intake Valve Actuation Oil Pressure not responding
• 285-07 to 290-07 Intake Valve Actuator not responding
• 358-01 Low Intake Valve Actuation System Oil Pressure
Expected Result:
One or more of the diagnostic codes are logged.
Results:
• 283-07 – Proceed to Test Step 5.
• 285-07 to 290-07 – Proceed to Test Step 9.
• 385-01 – Proceed to Test Step 6.
• Not OK – None of the diagnostic codes are logged. STOP.
Test Step 5. Check the Intake Valve Actuation Oil Pressure Solenoid
A. Turn the key switch to the OFF position.
B. Remove the intake valve actuation oil pressure solenoid from the engine.
C. Inspect the solenoid and clean the solenoid.
D. Reinstall the solenoid.
E. Turn the keyswitch to the ON position.
F. Clear all logged diagnostic codes.
G. Start the engine and allow the engine to run for at least 30 seconds once the engine coolant temperature is greater than 20 C (68 F).
Expected Result:
There are no active diagnostic codes or logged diagnostic codes for the intake valve actuation oil pressure solenoid.
Results:
• OK – The intake valve actuation oil pressure solenoid is operating correctly. STOP.
• OK 285-07 to 290-07 also logged – Proceed to Test Step 9.
• OK 385-01 also logged – Proceed to Test Step 6.
• Not OK – The intake valve actuation oil pressure solenoid is not functioning correctly.
Repair: Replace the intake valve actuation oil pressure solenoid.
Clear all logged diagnostic codes.
Start the engine and allow the engine to run for at least 30 seconds once the engine coolant temperature is greater than 20 C (68 F).
Check for active diagnostic codes and logged diagnostic codes.
If replacing the solenoid fixes the problem, choose one of the previous results.
If there is still a diagnostic code, call an Engine Technical Communicator (TC).
STOP.
Test Step 6. Check the System Pressure
A. Start the engine. Allow the engine to warm up to operating temperatures. Coolant temperature should be greater than 60 C (140.0 F).
B. Access the “Intake Valve Actuator Test” in the “Diagnostic Tests” under the “Diagnostic” menu.
C. After you adhere to the warnings, start the automatic “Intake Valve Actuator Test”.
Note: The test will cycle two times. Once the test is complete the engine speed will increase to 2100 rpm for 15 seconds. An “OK” or “Not OK” will be displayed once the test is complete.
Expected Result:
All cylinders indicate “Not OK” during the “Intake Valve Actuator Test”.
Results:
• OK – All cylinders indicate “Not OK”. Proceed to Test Step 7.
• Not OK – One or more cylinders indicate “OK”.
Proceed to Test Step 10.
Test Step 7. Perform a Leak Test
A. Turn the key switch to the OFF position.
B. Disconnect the front valve cover connector and the rear valve cover connector.
C. Disconnect the intake valve actuation pressure solenoid.
D. Remove the valve covers.
E. Wipe all of the engine oil away from the following components:
• Face seals for the intake valve actuators
• Intake valve actuation oil pressure solenoid
• Connection between the cylinder head and the valve cover base
• Plugged ports on the intake valve actuators
• Intake valve actuator solenoids
F. Crank the engine.
Note: Do not crank the engine for more than 20 seconds.
G. Check for oil leaks around all of the components under the valve cover.
Results:
• OK – No leaks were detected. Proceed to Test Step 8.
• Not OK – A leak was detected.
Repair: Determine the source of the leak.
Repair the leak.
Verify that the repair eliminates the problem.
STOP.
Test Step 8. Check the Check Valve
Note: Do not perform this procedure on engines with serial numbers (S/N: KCB1-512) and (S/N: KCA1-454).
A. Remove the intake valve actuation system check valve. Refer to Disassembly and Assembly, “Check Valve – Remove”.
B. Inspect the check valve. Look for debris that could cause the check valve to stick. Also check that the parts are in good repair.
Expected Result:
The check valve is OK.
Results:
• OK – The check valve is OK.
Repair: Replace the intake valve actuation oil pressure sensor.
Verify that the repair eliminates the problem.
STOP.
• Not OK – The check valve is damaged.
Repair: Replace the check valve.
Verify that the repair eliminates the problem.
STOP.
Test Step 9. Perform the “Intake Valve Actuator Test”
A. Start the engine. Allow the engine to warm up to operating temperatures. Coolant temperature should be greater than 60 C (140.0 F).
B. Access the “Intake Valve Actuator Test” in the “Diagnostic Tests” under the “Diagnostic” menu.
C. After you adhere to the warnings, start the automatic “Intake Valve Actuator Test”.
Note: The test will cycle two times. Once the test is complete the engine speed will increase to 2100 rpm for 15 seconds. An “OK” or “Not OK” will be displayed once the test is complete.
Expected Result:
All cylinders indicate “OK” during the “Intake Valve Actuator Test”.
Results:
• OK – All cylinders indicate “OK”.
Repair: Warm the engine until the engine coolant temperature reaches 75 C (167.0 F).
Repeat the “Intake Valve Actuator Test”.
If all cylinders indicate “OK”, clear the logged diagnostic codes and return the vehicle to the customer.
If one or more cylinders indicate “Not OK”, proceed to Test Step 10.
• Not OK – One or more cylinders indicate “Not OK”. Proceed to Test Step 10.
Test Step 10. Check the Lash Settings for the Intake Valve Actuator
A. Turn the key switch to the OFF position.
B. Allow the engine to cool.
C. Remove the valve cover(s) from the engine.
D. Check the lash settings for the intake valve actuators. Refer to Testing and Adjusting for the proper procedure.
Expected Result:
The lash settings are within the specification.
Results:
• OK – The lash settings are within the specification.
Proceed to Test Step 11.
• Not OK – The lash settings are not within the
specification.
Repair: Adjust the lash settings. Refer to Testing and Adjusting for the proper procedure.
Repeat the “Intake Valve Actuator Test”.
If all cylinders indicate “OK”, return the vehicle to the customer.
Verify that the repair eliminates the problem.
If one or more cylinders indicate “Not OK” proceed to Test Step 11.
Test Step 11. Perform a Leak Test
A. Turn the key switch to the OFF position.
B. Disconnect the front valve cover connector and the rear valve cover connector.
C. Disconnect the intake valve actuation pressure solenoid.
D. Remove the valve covers.
E. Wipe all of the engine oil away from the following components:
• Face seals for the intake valve actuators
• Intake valve actuation oil pressure solenoid
• Connection between the cylinder head and the valve cover base
• Plugged ports on the intake valve actuators
• Intake valve actuator solenoids
F. Crank the engine.
Note: Do not crank the engine for more than 20 seconds.
G. Check for oil leaks around all of the components under the valve cover.
Expected Result:
There are no detected leaks.
Note: Oil may leak from the bleed orifice on the intake valve actuator assembly.
Results:
• OK – There are no detected leaks. Proceed to Test Step 12.
• Not OK – There are detectable oil leaks under the valve cover.
Repair: Determine the cause of the leak.
Repair the leak.
Verify that the repair eliminated the problem.
STOP.
Test Step 12. Check the Check Valve
Note: Do not perform this procedure on engines with serial numbers (S/N: KCB1-512) and (S/N: KCA1-454).
A. Remove the intake valve actuation system check valve. Refer to Disassembly and Assembly, “Check Valve – Remove”.
B. Inspect the check valve. Look for debris that could cause the check valve to stick. Also check that the parts are in good repair.
C. Disconnect the intake valve actuation pressure solenoid.
D. Remove the valve covers.
E. Wipe all of the engine oil away from the following components:
• Face seals for the intake valve actuators
• Intake valve actuation oil pressure solenoid
• Connection between the cylinder head and the valve cover base
• Plugged ports on the intake valve actuators
• Intake valve actuator solenoids
F. Crank the engine.
Note: Do not crank the engine for more than 20 seconds.
G. Check for oil leaks around all of the components under the valve cover.
Expected Result:
There are no detected leaks.
Note: Oil may leak from the bleed orifice on the intake valve actuator assembly.
Results:
• OK – There are no detected leaks. Proceed to Test Step 12.
• Not OK – There are detectable oil leaks under the valve cover.
Repair: Determine the cause of the leak.
Repair the leak.
Verify that the repair eliminated the problem.
STOP.
Test Step 12. Check the Check Valve
Note: Do not perform this procedure on engines with serial numbers (S/N: KCB1-512) and (S/N: KCA1-454).
A. Remove the intake valve actuation system check valve. Refer to Disassembly and Assembly, “Check Valve – Remove”.
B. Inspect the check valve. Look for debris that could cause the check valve to stick. Also check that the parts are in good repair.
Expected Result:
The check valve is OK.
Results:
• OK – The check valve is OK. Proceed to Test Step 13.
• Not OK – The check valve is damaged.
Repair: Replace the check valve.
Verify that the repair eliminates the problem.
STOP.
Test Step 13. Inspect the Hardware Inspect the suspect intake valve actuator unit.
A. Remove the suspect intake valve actuator.
B. Inspect the face seal for damage.
C. Inspect the intake valve actuator for damage.
D. Check for debris in the intake valve actuator assembly.
Expected Result:
The intake valve actuators are free of debris and the face seals are OK.
Results:
• OK – There is no debris in the assembly and the face seals are not damaged.
Repair: Replace only the suspect intake valve actuator assembly. Refer to Testing and Adjusting for the proper procedure.
Verify that the repair eliminates the problem.
STOP.
• Not OK – There is debris in the assembly or there is a damaged face seal.
Repair: Replace any damaged face seals.
Remove any debris from the intake valve actuator assembly.
Verify that the repair eliminates the problem.
STOP.