EGR pipe crack/gas leaks

EGR PIPE CRACK/GAS LEAKS

Model

Defender

Reference

Service action 381

Bulletin text

SERVICE ACTION BULLETIN

Circulation: X Indicates to whom this information should be circulated SERVICE MANAGER X SERVICE RECEPTION PARTS MANAGER WARRANTY MANAGER

Discovery Td5 Defender Td5 (Engine Number Range)

PROBLEM:

EGR PIPE CRACK/GAS LEAKS

CAUSE:

During engine manufacture the EGR pipe may be under stress due to incorrect tightening of the pipe fixings.

ACTION:

At Pre-delivery inspection, remedial warranty work or at the first service the EGR pipe must be inspected for cracks/sooting of the pipe and either replaced or slackened off and repositioned, refer to the procedure below.

PROCEDURE

A number of vehicles have been reworked at Land Rover, these vehicles have been identified by the application of WHITE paint applied to the heads of the flanged bolts securing the EGR pipe to the exhaust manifold (see illustration opposite).

No further action is required on these vehicles if WHITE paint is visible.

If further inspection of the EGR pipe is required the engine cover must be removed on both Discovery and Defender models.

Discovery models will also require the fan cowl to be removed and the expansion tank fixings released.

A warranty claim for inspection/check must be made to remove the vehicle from the warranty database.

SERVICE ACTION BULLETIN No: A/D381

EN Bull. N o : A/D381

AFFECTED RANGE:

XA230711 to YA238634 XA176706 to YA179425 10P38002A to 10P42129A

Rover Group 1999

Procedure 1 1. If WHITE paint is not evident on the flanged bolts, inspection of the pipe must be undertaken to ensure it has not fractured. 2. Visually inspect the EGR pipe convolutes to identify if any ‘Sooting’ of the exterior of the pipe is evident. If no ‘Sooting’ is visible the pipe has not fractured but requires slackening off and re-positioning to remove any stress, following the sequence below. 3. Slacken the ‘C’ clamp bolt (Fig 3), flanged bolts at the exhaust manifold (Fig 2) and the centre bracket bolts (Fig 1) supporting the EGR pipe at the front of the cylinder head. 4. IMPORTANT

NOTE:

The following tightening process must be followed very carefully to eliminate stress within the EGR pipe. 5. Tightening Procedure: a) Ensure all fixings are finger tight. b) Tighten the ‘C’ clamp bolt to 4 to 6 Nm (Fig 3). c) Tighten the bracket securing bolts to 7 to 10 Nm (Fig 1). d) Tighten the two exhaust manifold flanged bolts to 7 to 10 Nm (Fig 2). Discovery : Tighten expansion tank fixings, replace fan cowl and refit engine cover. Defender : Refit engine cover.

Procedure 2 1. Visually inspect the EGR pipe convolutes to identify if any ‘Sooting’ of the exterior of the pipe is evident, if ‘Sooting’ is visible the EGR pipe must be replaced. 2. Remove all fixings, ‘C’ clamp bolt and clamp, flanged bolts (discard the flange bolts) at the exhaust manifold and the centre bracket bolts supporting the EGR pipe at the front of the cylinder head. 3. Fit new EGR pipe noting that new flange bolts WAO100000 must be fitted and a new cup gasket WAL100240 to the ‘C’ clamp. 4. Follow the tightening sequence as described in Procedure 1 - instruction 5 above.

SERVICE ACTION BULLETIN No: A/D381
Rover Group 1999

PARTS INFORMATION:

WAP101220 - EGR pipe - 1 off WAO100000 - Bolts - 2 off WAL100240 - Cup gasket - 1 off

WARRANTY CLAIMS:

UK - Complaint code A381 Option code A = 00.20 hour check only Option code B = 00.30 hour check & adjust Option code C = 00.40 hour check & replace

Europe/Rest of World - Complaint code D381 17.45.89/28 = 00.20 hour check only 17.45.89/29 = 00.30 hour check & adjust 17.45.89/30 = 00.40 hour check & replace

SERVICE ACTION BULLETIN No: A/D381
Rover Group 1999