EGR Pipe - Removing Due to Redundancy
303-36DATE 11/99
MODEL
1997 MY XK8 Range
VIN
001036
011461
Removing Redundant EGR Pipe - Authorized Modification - Service Action S831
Issue:
Some 1997 MY XK8 vehicles within the above VIN range may experience perforation or cracking of the Exhaust Gas Recirculation (EGR) transfer pipe.
Since the EGR system is not actually required to meet exhaust emission standards, the pipe can be removed. The openings in the exhaust manifold and EGR valve should then be blanked off by plates and gaskets. This bulletin provides a full procedure.
Action:
The modification of affected vehicles should be performed at the next service opportunity. If Service Action S819 or S471 was previously performed on the vehicle, the ECM has been reprogrammed so that the EGR valve is driven to the 'closed' position each time the engine is started. Since a check is made that the valve is in the 'closed' position, the EGR Valve itself must remain on the vehicle.
^ A vehicle that has had no reflash performed must be upgraded to S479 after completing S831. Refer to technical bulletin 303-35 for S479.
^ A vehicle that has had S819 performed should be upgraded to S479 after completing S831.
^ If the vehicle has had S471 performed, no reflash is necessary.
MODIFICATION PROCEDURE
1. Check the B-pillar for an S831 label (Illustration 1). If no S831 label is present, open the hood and cover the fenders.
2. For access remove the air intake duct/mass air flow sensor/air cleaner cover assembly.
3. Remove the bolts that secure the E.G.R. transfer pipe to the E.G.R. valve.
4. Remove the nuts that secure the E.G.R. transfer pipe to the exhaust manifold.
5. Remove and discard the E.G.R. transfer pipe.
6. Remove all residues from the E.G.R. valve and exhaust manifold.
7. Install a blanking plate and gasket on both the E.G.R. valve and the exhaust manifold, from where the pipe has been removed. Use the original nuts and bolts that previously retained the pipe.
Torque wrench setting - nuts & bolts: 18 - 24 Nm.
8. Reinstall the air intake duct/mass air flow sensor/air cleaner cover assembly.
9. Remove the fender covers and close the hood.
INSTALL AUTHORIZED MODIFICATION LABEL
Write the date and your dealer number on the S831 authorized modification label (Illustration 1). Apply the label to the B-pillar on XK8 vehicles. (This label will immediately indicate to any other dealer that the vehicle concerned has already been rectified). Do not cover or remove any stickers referring to Reflash modifications.
California Dealers: Fill Out and place the salmon colored "Vehicle Emission Recall - Proof of Correction" form (Illustration 2, part no.5 CAL/RCL) in the vehicle glove compartment.
Parts Information:
DESCRIPTION PART NUMBER QTY
Blanking plate XR8 14038 2
Gasket NCA4 771BE 2
S831 authorized modflcation label S831/STK 1
Warranty Information:
NOTE:
Always perform a DCS claim search first to determine whether this service action has been performed on this vehicle. The warranty selection under the vehicle inquiry will give a listing of all claims against the vehicle. If S831 appears in the fault code field, do not perform this service action.
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-l warranty claim form.