Action

Refer to the charts to determine the appropriate course of action.

Note:
In the case of customer brings to the dealer a vehicle that exhibits a drivability concern that the recall action does not eradicate, normal diagnostic procedures can be followed as necessary to determine the root cause. The completion of any subsequent repairs are subject to normal New Car Warranty or Select Edition Warranty, or customer pay authorization as appropriate.

Remove the ECM from the vehicle by the following procedure.

1. Connect the WDS to the vehicle's data link connector.

2. Record any diagnostic trouble codes stored in the ECM, then clear them from the system.

3. Turn the ignition switch to 'off', wait 20 seconds before continuing with this procedure.

4. Note customer settings such as radio stations.

5. Open the luggage compartment, remove the cover from the battery and disconnect the battery ground cable.

REMOVING ECM

1. Open the right hand door and remove the carpet from the foot well.

2. Remove the ECM cover insulation pad.

3. Remove the securing nuts and remove the cover from the ECM.

4. Remove the ECM from its mounting, disconnect both harness connectors and remove the ECM from the vehicle.

5. Mark the VIN on the side of the ECM to prevent confusion when more than one ECM is being modified.

ISSUE 1 - REPLACING PROM

1. Check that the 'anti-back out' plate on the face of each harness connector is still in place after disconnecting the connector.

Note:
In the event of the anti-back out plate becoming loose or detached, secure it to the face of the connector, pressing it firmly in place.





Caution:
Perform the following operations at an antistatic workstation (previously supplied) while wearing a grounding wrist-strap (Illustration 1). Additional work mats can be sourced locally, such as Radio Shack cat. no. 910-3780.

2. Place the ECM on the anti-static work mat, with one flat face to the mat. Looking towards the two connectors, the red connector should be to the upper right, the black connector to the lower left.

3. Note the orientation of the top cover with its mounting lugs, relative to the ECM casing. Mark both the cover and casing, using a felt-tip marker pen, to assist when reassembling.

4. Remove the four retaining screws of the top ECM cover (i.e. the cover adjacent to the red connector) using a Torx 20 anti-tamper type bit. Remove the cover.





5. Remove the seven retaining screws of the printed circuit board (8, Illustration 2). Fold the printed circuit board away from the body of the ECM unit and support it on a block of wood (6, Illustration 2) so that no strain is placed on the ribbon connectors (7, Illustration 2). Allow a clearance space (5, Illustration 2) so that no damage can occur from contact with the mounting brackets.

6. The modification kit contains two microchips, one each of the 28-pin (1, Illustration 2) and 32-pin (2, Illustration 2) design.

7. Remove the covers (4, Illustration 2) from the microchips on the printed circuit board. Remove each cover by applying a side-to-side rocking action, gripping the cover lightly with combination pliers midway along each long side.

Caution:
Do not touch the printed circuit board with the pliers, or mark the surface of the printed circuit board.








8. Remove the PROM microchips from the printed circuit board using a suitable proprietary removal/reinstallation tool (Illustrations 3 & 4).





9. When inserting the replacement PROM microchips, identify the 'half moon' cutouts in both the microchip and the socket on the printed circuit board (Illustration 5).

Caution:
Correct orientation is mandatory. The cutouts in both items must be aligned as the microchip is inserted into the socket.

10. The removed microchips should be set on one side, to be returned to Jaguar.

11. Identify and install the replacement 28-pin and 32-pin microchips from the modification kit to the appropriate sockets.





12. Use great care to achieve condition '1' in Illustration 6. The microchip must lie parallel to the printed circuit board, with all pins fully engaged into their corresponding locations in the socket.

Caution:
Permanent damage to the microchip is likely in conditions B or C. Malfunctions will occur with partial engagement, as in condition D.

13. Reinstall the original covers over the replacement PROM microchips.

14. Carefully fold the printed circuit board back to its original location on the casing of the ECM, ensuring that the connector is correctly aligned to its location in the casing. Install and tighten the seven securing screws. Torque setting: 2.25-2.82 Nm (20-25 lb in).

15. Reinstall the ECM cover on the case, aligning the marks made at step 3 of this workshop procedure, prior to removal of the cover. Install and tighten the four securing screws. Torque setting: 2.25-2.82 Nm (20-25 lb in).





16. Apply the PECUS label from the modification kit to the cover of the ECM. The new label must not obscure any existing label on the unit (Illustration 7).

Note:
Use this label for T493 also.

17. Reinstall the ECM in the vehicle, by a reversal of the process used for its removal.

18. Continue with the procedure for replacing the EGR valve.

ISSUE 2 - REPLACING EGR VALVE

1. Open the hood and place covers over the fenders.





2. Disconnect the EGR valve harness connector (Illustration 8).

3. Remove the EGR valve securing bolts.

4. Remove the EGR valve and valve gasket.

5. Clean the valve mating faces.

6. To reinstall the new EGR valve and gasket, reverse the EGR valve removal process.

Note:
Care must be taken not to damage the EGR valve securing bolts. Torque figure: 23-27 Nm (17-20 lb ft).

7. Continue with the procedure for replacing the throttle spring.

ISSUE 3 - REPLACING THROTTLE RETURN SPRING

1. Disconnect the inner accelerator cable from the throttle assembly.

2. Remove the cruise control linkage pin and circlip.

3. After removing the three Torx head screws that retain the throttle assembly cap to the pedestal, carefully remove the cap sub-assembly. Note the position of the straight extension of the throttle return spring.





4. Unhook the throttle torsion spring (Illustration 9) from the throttle shaft actuator and then remove the spring and the sleeve from the shaft.

5. Remove the sleeve from the spring and discard the spring.

6. Insert the sleeve into the replacement spring. Install the sleeve and spring on the throttle shaft and hook the spring on to the actuator.

Note:
The throttle return spring must be tensioned, (pre-loaded) by rotating the straight extension one full turn counterclockwise until it can be installed in the same position as the original spring.

7. Carefully reinstall the cap to the throttle assembly noting the lever location, and install and tighten the screws.

8. Reconnect the cruise control linkage.

9. Reconnect the accelerator cable to the throttle assembly.

10. Check the operation of the throttle assembly.

11. Remove fender covers, reconnect the battery, reinstall the battery cover, and close the lid of the luggage compartment. Reset the vehicle clock and customer preferences.

12. Using the WDS, perform the oxygen sensors orientation test. (Select set-up and configuration, engine and transmission, oxygen sensor orientation.)

13. Using the WDS, perform the throttle potentiometer adaptation test.

Note:
During the throttle pot adaptation test portion of the engine set-up procedure, the WDS will ask if a new throttle position sensor has been installed. Answer this question with YES even though the existing sensor is being reused. This action will allow the WDS to reset a larger set of parameters.

14. Check for the presence of any erroneous diagnostic trouble codes (DTCs). If DTCs are present, they should be recorded, and then cleared.