Exhaust downpipe rattle - bracket

EXHAUST DOWNPIPE RATTLE - BRACKET

Model

New 214/216, 200Vi, New 414/416, 216 Cabriolet/Coupe, 416 Tourer, 214/414

Affected vehicles

Applies to: • • All New 200 vehicle range with 1.4, 1.6 and 1.8 ‘K16’ engines. • • All New 416 vehicle range with ‘K16’ engines. • • New 414 with ‘K16’ engines, except with engine prefix 14K4FH61 and 14K4FH62. • • All current range 216 Cabriolet/Coupe and 416 Tourer with ‘K16’ engines. • • 214/414 with ‘K16’ engine prefix’s 14K2DK73, 14K4FK74, 14K4FK78 only. Note: Can be applied only to engines having two tapped casting protrusions on the side of the cylinder block adjacent to the manifold / downpipe joint. This casting modification coincided with the introduction of ‘K’ Series with damp cylinder liners. RE-ISSUE INFORMATION: Change to warranty complaint code. Note added reference unnecessary downpipe replacement.

Reference

R7873bu

Bulletin text

New 214/216, 200Vi, New 414/416, 216 Cabriolet/Coupe, 416 Tourer, 214/414

AFFECTED RANGE:

Applies to: • • All New 200 vehicle range with 1.4, 1.6 and 1.8 ‘K16’ engines. • • All New 416 vehicle range with ‘K16’ engines. • • New 414 with ‘K16’ engines, except with engine prefix 14K4FH61 and 14K4FH62. • • All current range 216 Cabriolet/Coupe and 416 Tourer with ‘K16’ engines. • • 214/414 with ‘K16’ engine prefix’s 14K2DK73, 14K4FK74, 14K4FK78 only.

Note: Can be applied only to engines having two tapped casting protrusions on the side of the cylinder block adjacent to the manifold / downpipe joint. This casting modification coincided with the introduction of ‘K’ Series with damp cylinder liners.

RE-ISSUE INFORMATION: Change to warranty complaint code. Note added reference unnecessary downpipe replacement.

PROBLEM:

EXHAUST DOWNPIPE RATTLE - BRACKET

Complaints of rattle, vibration or resonance at various engine speeds. May be more prominent at around 2400 RPM and in some instances only when engine is cold. May also be described as boom on overrun.

CAUSE:

Exhaust downpipe unsupported.

ACTION:

Fit Bracket Exhaust Downpipe (kit) GEX 13002

Fitting instructions: 1. Remove the two manifold to down pipe nuts nearest to the cylinder block.

2. Position bracket over studs.

Bull. N o : 0002

2 24/09/97

3. Secure opposite end of bracket to the 2 adjacent tapped casting bosses in the cylinder block, use the 2 X M10 flange bolts supplied.

4. Disconnect oxygen sensor cable and fit the heat resistant sleeve provided to cable, slide sleeve fully up to the sensor body.

5. Fit the remaining 2 X M10 flange nuts to the protruding manifold studs and tighten to secure bracket, torque to 55Nm.

6. Finally tighten the bracket to block flange bolts to 55Nm.

7. Re-connect oxygen sensor.

Downpipe replacement: It should not be necessary to replace exhaust down pipe in addition to the fitment of bracket. Always apply this bulletin first and assess improvement. Only in exceptional instances will it be required to replace downpipe.

PARTS INFORMATION:

GEX 13002 - Bracket Exhaust Downpipe (kit)

WARRANTY CLAIMS: Use Complaint Code: 2S3K Use S.R.O. 30.15.88/30 Time allowed: 0.50 Hrs