Action:

All 1990 MY Sedans are to be updated during normal maintenance or on a complaint basis, using the following procedure:

FIG. 1:

^ When any vehicle up to VIN 631322 is in for service, inspect the EGR valve housing, (fig. 1). The three punch marks indicates the vehicle has been modified. If it has not been modified, proceed with this operation.

FIG. 2:

^ Disconnect the EGR pipe union nut (fig. 2 A) to threaded adaptor (fig. 2 D), at the exhaust manifold.

^ Loosen and remove the threaded adaptor from the EGR valve. Remove the copper washer (fig. 2 E).


NOTE: If a brass adaptor is installed, replace it with the new steel adaptor (EBC 3930).

FIG. 2:

A. Exhaust Manifold Connection
B. Inlet Manifold Connection
C. Olive
D. Adaptor
E. Steel Washer
F. Manifold Boss Connection
G. Sealing applications

^ Clean the threads of the EGR housing, (fig. 2 F).

^ Apply exhaust sealant (JLM 10602) to all threads (internal and external) as indicated in fig. 2 G.

^ Install a new steel washer (EBC 5185) to the threaded adaptor.

^ Install and tighten adaptor into EGR valve housing (refer to "Torque Specifications").

^ Install EGR pipe into the adaptor. Do not tighten yet.

^ Raise the vehicle on a lift.


NOTE: Perform the following procedure from underneath the vehicle.


^ Disconnect the EGR pipe (fig. 2 B) from the threaded adaptor at the inlet manifold.

^ Remove the threaded adaptor from the manifold housing.

^ Remove the copper washer.


NOTE: If a brass adaptor is installed, replace it with the new steel adaptor (EBC 3930).


^ Clean the adaptor threads and inlet manifold housing threads.

^ Apply exhaust sealant (JLM 10602) to the pipe sealing olive and threaded adaptor as indicated in fig. 2 G.

^ Install the new steel washer (EBC 5185) to the threaded adaptor.

^ Install the threaded adaptor to the inlet manifold and tighten (refer to "Torque Specifications").

^ Install EGR pipe to the adaptor and tighten (refer to "Torque Specifications").

^ Clean any excess sealant from joint.

^ Lower the vehicle.

^ Tighten the EGR pipe at the adaptor (refer to "Torque Specifications") and clean any excess sealant from the joint.

^ Mark the EGR valve housing for identification of this repair with three punch marks as indicated in fig. 1.

^ Check the VCM for the presence of fuel fail codes 26 or 44. If codes are present, erase the ECU memory by disconnecting the vehicle battery.