Campaign - MIL ON DTC P0441 Set
05.1-22DATE
7/96
Sedan Range
MODEL:
1996 MY
Sedan (4.0L) NA
VIN:
USA 772231-776270
Can. 772231-784296
MIL Illumination - DTC P0441 -
Service Action S672
ISSUE:
Some 1996 MY Sedan Range vehicles within the above VIN ranges may experience illumination of the Malfunction Indicator Lamp (MIL) caused by DTC P0441 being falsely registered in the Engine Control Module (ECM).
On US market Sedan Range vehicles, the condition could occur on Vanden Plas (long wheelbase) vehicles only. On Canadian market Sedan Range vehicles, it can occur on both XJ6 and Vanden Plas (short wheelbase and long wheelbase) vehicles.
This condition can be rectified by replacing both of the Programmable Read Only Memories (PROMs) with new PROMs from the appropriate modification kit.
ACTION:
Replace the PROMs on all vehicles within the above VIN ranges. This action should be performed if possible, during PDI, prior to the sale of the vehicle.
NOTE:
Always perform a DCS claim search first to determine whether this service action has already been performed on the vehicle. The warranty selection under the Vehicle Inquiry will give a listing of all claims against the vehicle. If S672 appears in the fault codes field, do not perform this service action.
For vehicles already in service, the modification should be done at the first service opportunity, or in case of a customer complaint.
PREPARATION
1. Connect the PDU to the vehicle and check for any DTCs stored in the ECM.
2. Record any DTCs found on an OBDII report form (S-93), then clear them from the system. Any DTCs other than P0441 must be diagnosed separately.
3. Turn the ignition OFF. Wait 20 seconds, then disconnect the vehicle battery.
REMOVING ECM
1. Remove the right side A-pillar trim.
2. Remove the trim panel mounting bracket.
3. Remove the ECM retaining bolt and disengage the upper spade mounting of the ECM from the slot in the A-pillar.
4. Disconnect both harness multi-plug connectors from the ECM and remove the ECM from the vehicle.
REPLACING PROM
^ ECM tools required:
^ One Anti-static pad, Part No. JAG 205/ST010
^ One PROM removal tool, Part No. JAG 999/ND
^ One TX 20 Torx Tamper-proof screw bit, JAG 20/TORX
CAUTION!
The following steps should only be carried out while working at an anti-static workstation (Illustration 1) and wearing a grounding wrist strap.
1. Position the ECM on the anti-static workmat so that when facing the multiplugs, the red multi-plug is at the upper right and the black multi-plug to the lower left.
2. Note the position of the top cover with its mounting tab to the ECM housing. Mark both the cover and the casing using a felt tip marker to assist reassembly. Remove the four tamper resistant retaining screws of the top cover (the cover adjacent to the red multi-plug) using a Torx 20 Anti-Tamper screw bit.
3. Obtain a wooden block approximately 6 x 6 x 1 inches. Remove the seven retaining screws of the printed circuit board (Illustration 2). Lift the printed circuit board and support it on the wooden block so that no strain is applied to the ribbon connectors. Allow a clearance space so that no damage can occur from contact with the mounting brackets.
4. Remove the appropriate PROM covers by lightly gripping the PROM cover with a pair of pliers and using a side to side rocking action.
5. Use a suitable chip removal tool to carefully remove both PROM chips from the printed circuit board (Illustration 3). The PROM removal tool supplied may differ from that shown in the illustration.
6. Before installing the new microchip(s), identify the semicircular cutouts in both the chip and the socket on the printed circuit board (Illustration 4). The two cutouts must be aligned as the chip is inserted into the socket.
NOTE:
To aid in installing the PROM, an installation tool can be sourced at a local electronics supply store.
Careful manual alignment and installation methods must be used at this point in the procedure.
7. Identify and install the replacement 28-pin chip from the kit into the 28-pin socket and the 32-pin chip into the 32-pin socket.
CAUTION!
The microchip MUST lie parallel to the printed circuit board with all the pins engaged into the socket (condition A, Illustration 5). Permanent damage to the chip is likely in conditions B or C. Malfunctions will occur with partial engagement as in condition D.
8. Install the original cover(s) over the PROM chip(s).
9. Carefully fold the printed circuit board back into its original location on the housing of the ECM. Make sure the multi-plug is correctly aligned with its location in the housing. Install the seven retaining screws. Torque the screws to 20 - 25 lb. in. (2.25 - 2.82 Nm).
10. Install the ECM cover on the housing aligning the marks made during disassembly. Install the four mounting screws. Torque the screws to 20 - 25 lb. in. (2.25 - 2.82 Nm).
11. Apply the PECUS label from the kit to the cover near the existing labels without covering them (Illustration 6).
12. Install the ECM by reversing the removal procedures.
13. Connect the battery and reset the vehicle clock.
14. Start the vehicle and perform an adequate road test to verify proper engine operation. Use the PDU to check the orientation of the oxygen sensors and perform the engine setup only if a driveablity complaint exists.
PARTS INFORMATION
PARTS CROSS REFERENCE
WARRANTY INFORMATION
CLAIM SUBMISSION PROCEDURE:
Warranty summary codes have been assigned to this service action in order to simplify claim submission. The dealership will be reimbursed the parts and labor time allowance as indicated.
DCS DEALERS
Submit claims using the appropriate summary code for the vehicle model and work performed. Follow standard campaign submission procedures.
NON-DCS DEALERS
Submit claims on the Recall Campaign Summary form W-25. Enter the appropriate summary code for the vehicle model and work performed in the Repair Code column. Do not use the W-1 warranty claim form.