Recall - EGR Pipe Replacement: Overview

303-S701

V8 XJ Series

DATE 01/01
Amended 01/04

MODEL
1998-99 MY
XJR

VIN
812256-878717

Check Engine MIL Illuminated/Excess Engine Noise - Replace Cracked EGR Transfer Pipe - Service Action S701

Remove and destroy Bulletin 303-S701 dated 01101. Replace with this Bulletin.

Revisions are shown with black bars and asterisks.

ISSUE:

* This Service Action is being reissued due to low completion rates. As a result, Jaguar will be contacting customers directly.* Some 1998-99 MY XJR vehicles within the above VIN range may experience illumination of the check engine light and/or customer complaints of excess engine noise. This condition can be caused by a cracked EGR transfer pipe.

Action:

In order to reduce potential customer complaints the EGR transfer pipe must be replaced on all vehicles within the above VIN range at the next service opportunity or in case of a customer concern.

EGR PIPE REPLACEMENT PROCEDURE

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

2. Remove the air intake duct mass air flow sensor and air cleaner as an assembly.





3. Loosen and remove the fasteners securing the EGR transfer pipe to the EGR valve (Illustration 1).

4. Reposition the EGR transfer pipe for access to the gasket.

5. Remove the gasket from between the EGR transfer pipe flange and EGR valve.

6. Loosen and remove the bolts securing the EGR transfer pipe to the right hand exhaust manifold.

7. Remove the EGR transfer pipe from the right exhaust manifold studs.

8. Remove the gasket from the right exhaust manifold studs.

9. Clean the relevant components and mating faces.

10. Position a new gasket on the right exhaust manifold studs.

11. Secure the new EGR transfer pipe to the right exhaust manifold studs.

12. Align the EGR transfer pipe (via convolutions) with the EGR valve.

13. Position a new gasket between the EGR transfer pipe flange and the EGR valve.

14. While maintaining the gasket in position align the EGR transfer pipe flange with the EGR valve and secure the bolts.

15. Reinstall the air intake duct mass airflow sensor and air cleaner assembly.

APPLYING MODIFICATION LABEL








* Fill out an authorized modification label (Illustration 2), enter the dealer number and date an the authorized modification label and apply the label under the hood as shown in (Illustration 3).*

PROOF OF CORRECTION FORM





* California Dealers (and any other states where required): Fill out and place the salmon colored "Vehicle Emission Recall - Proof of Correction" form (Illustration 4, part no. S CAL RCL) in the vehicle glove compartment.*

* Note:
Refer to Administration Bulletin 6-94, for information on obtaining additional Authorized Modification labels.*





Parts Information





Warranty Information

* NOTE:
Always perform a DDW claim search first to determine whether this service action has been performed on this vehicle. The "Review Claim History" function will provide a listing of all claims against the vehicle. If this service action number appears in the program code field, do not perform this service action.*