303-35 (S479) Amendment 2

303-35 (S479) Amendment 2
V8 XJ Series/XK8
DATE 11/99
Amended 04/01
303-35
TECHNICAL BULLETIN
SERVICE
Difficult Cold Start – Normally Aspirated
Engines – ECM Flash Reprogramming –
Service Action S479
MODEL
VIN
1997-99 MY
XK8 Range
1998-99 MY
V8 XJ Series NA
See text
Remove and destroy Bulletin 303-35, amended 03/00.
Replace with this Bulletin.
The reference to Service Action S472 has been
removed since the service action has been cancelled.
Issue:
Since the launch of Service Actions S819 and S471 further developments in software have
become available.
A new PDU disk is now available, labeled “XK8/XJ Series DRIVEABILITY supercedes S471”
‘S479’, which may be used to reprogram the ECM of the following vehicles:
•
1997-98 MY XK8 VIN 001036-020733
•
1998 MY V8 XJ Series VIN 812256-819771 NORMALLY ASPIRATED ENGINES
ONLY
•
1999 MY XK8 VIN 031303-042775 NORMALLY ASPIRATED ENGINES ONLY
•
1999 V8 XJ Series VIN 853936-878717 NORMALLY ASPIRATED ENGINES ONLY
Note: 1998 XK8 VIN 020733-031302 and V8 XJ Series VIN 819772853935 do not have ECMs that can be reflashed.
S479 does not apply to supercharged vehicles.
Customers may complain of difficulty in starting the engine, from cold, on vehicles within the
above VIN ranges, under certain running conditions. In some instances a no-start condition may
be reported. Many of the affected vehicles may have been reprogrammed on a previous
occasion, under Service Action S819 or Service Action S471. Since Service Action S479
supersedes both Service Action S819 or Service Action S471 do not perform Service Action
S819 or Service Action S471.
Date of issue 11/99 Amended 04/01
Bulletin Number 303-35 Page 1 of 15
Note the following service guidelines:
1. On vehicles which have not been previously reprogrammed to S819 or S471, perform S479
at the next service opportunity, or as soon as can be arranged in case of a customer
complaint.
2. On vehicles previously reprogrammed to S819, but not reprogrammed to S471 condition,
perform S479 on all affected vehicles at the next service opportunity, or as soon as can be
arranged in case of a customer complaint.
3. On vehicles previously reprogrammed to S471, perform S479 on a customer complaint
basis ONLY in the case of additional cold start complaints.
4. On vehicles previously reprogrammed to S819 and S471, S479 should be performed on a
customer complaint basis only.
5. On 1999 MY vehicles, S479 should be performed on a customer complaint basis only (since
they already are at the S471 software level).
Note that Service Action S831 (technical bulletin 303-36) references this Service Action. It may
be necessary to perform this S479 reflash on some XK8 vehicles which have been modified to
remove a cracked EGR pipe according Service Action S831. This is fully detailed in technical
bulletin 303-36.
Page 2 of 15
Bulletin Number 303-35
Date of issue 11/99 Amended 04/01
Action:
PROCEDURE
CAUTION: Follow this PDU procedure in detail as described below.
Any deviation from the procedure can result in a failure mode in the Engine
Management System ECM that is irrecoverable.
Note: Check for a S479 sticker (Illustration 13) on the B-post of XK8
vehicles or near the left hood hinge on V8 XJ Series. Always perform a DCS
claims 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 S479 appears in the
fault code field, do not perform this service action.
1.
Open the hood and the luggage compartment lid.
2.
Install fender covers and then remove the battery cover. Ensure that battery voltage is
adequate for continued testing.
CAUTION: The engine coolant and air intake temperatures must be
below 50°C (122°F) for the following operation. Do not attempt to trick the
system by cooling the sensors. The sensors will return to actual temperatures
during the process. This will abort the program and can ruin the ECM.
3.
4.
Connect the PDU to the vehicle and check for any stored DTCs in the ECM. Record any
DTCs found and then delete them. Disconnect the PDU.
On XK8 vehicles within VIN range 018108-020733 or 031303-042775 only, remove the
cover from the fuse box on the driver side of the fascia. Remove fuse no. 6 (tan, 5 amps sixth fuse from the top in the row of 9 fuses) for the Key Transponder Module (KTM).
PROGRAMMING SCREEN
ILLUSTRATION 1
5.
On all vehicles, connect the PDU to the base station and then insert the CD-ROM into the
base station drive. Highlight ‘ECM Programming’ and select the check icon (Illustration
1). (The Main Menu will appear with only one option, ‘ECM Programming’. Select this
option and the check icon to continue.
Date of issue 11/99 Amended 04/01
Bulletin Number 303-35 Page 3 of 15
ILLUSTRATION 2
6.
Enter the VIN and other vehicle information.
ILLUSTRATION 3
7.
Select the market specification “FEDERAL” for US and Canadian vehicles.
Page 4 of 15
Bulletin Number 303-35
Date of issue 11/99 Amended 04/01
ILLUSTRATION 5
8.
Select the engine variant “4.0L NORMALLY ASPIRATED”. Do not select supercharged.
ILLUSTRATION 5
9.
Confirm the selected data (example only)
Date of issue 11/99 Amended 04/01
Bulletin Number 303-35 Page 5 of 15
6.
When the ‘Connect Cables’ command (Illustration 3) appears, connect the MPA to the
PDU.
Select the check icon. The PDU will initiate the MPA.
CONNECT MPA SCREEN
ILLUSTRATION 6
7.
When the ‘Connect Cables’ command appears, connect the MPA/PDU to the vehicle
diagnostic link connector (Illustration 5). The application then checks the Engine Coolant
Temperature (ECT) and the Intake Air Temperature (IAT) to ensure they are both below
50°C before allowing the application to proceed.
If either of the two temperatures are above 50°C, the temperature would be displayed on the
PDU screen along with the message, ‘Both temperature sensors must read between 0
and 50 degree Celsius to continue; press TICK to abort.’ (Tick = check icon). After
aborting, the application would return to the Main Menu.
CONNECT TO VEHICLE SCREEN
ILLUSTRATION 5
Page 6 of 15
Bulletin Number 303-35
Date of issue 11/99 Amended 04/01
8.
If both the ECT and the IAT are below 50°C, the application then performs a CAN system
check, followed by a SCP system check. The application indicates when the tests have been
passed. If an error is found, the application will display the message, ‘Emissions related
fault codes are logged. Run Diagnostics’, the application would then return to the Main
Menu.
Note: The PDU screens indicate that the relays are black. However, on most
vehicles the relays are brown.
Note: On 1999 MY vehicles, the software will skips the steps (9-15) that
require removal of the fuse and relay. The following messages may appear:
“Performing check sum test” and “Flash programming voltage set”. No
action is required on the part of the operator. The PDU will continue the
reflash programming process.
REMOVE ECM RELAY SCREEN
ILLUSTRATION 6
9.
The application then indicates that the ECM relay (EMFR01) must be removed (Illustration
6). The Vehicle Data Viewer (VDV) display (select magnifying glass) will show the location
of the relay. On XK8 vehicles, the relay is located directly in the engine management fuse
box, in front of the ECM in the coolbox. On V8 XJ Series the relay is located in the engine
management fuse box on the left front fender.
After removing the ECM relay, select the check icon to continue.
Date of issue 11/99 Amended 04/01
Bulletin Number 303-35 Page 7 of 15
REMOVE RADIATOR FAN FUSE SCREEN
ILLUSTRATION 7
10. The application then indicates that the fuse (EMF012 for XK8, EMF014 for V8 XJ Series)
for the radiator fan module must be removed (Illustration 7). The VDV display will show
the location of the fuse. Engine management fuse box fuse no. 12 (10 Amp) for XK8.
Engine management fuse box fuse no. 14 (10 Amp) for V8 XJ Series.
After removing the fuse, select the check icon to continue.
REMOVE FUEL PUMP RELAY SCREEN
ILLUSTRATION 8
11. The application then indicates that the fuel pump relay (BTFR04) must be removed
(Illustration 8). The VDV display will show the location of the relay. The relay is located
in the trunk fuse box.
After removing the fuel pump relay, select the check icon to continue.
Page 8 of 15
Bulletin Number 303-35
Date of issue 11/99 Amended 04/01
REINSTALL ECM RELAY SCREEN
ILLUSTRATION 9
12. The application then indicates that the ECM relay (EMFR01) must be reinstalled
(Illustration 9).
After reinstalling the ECM relay, select the check icon to continue.
13. The flash process now proceeds with the progress being displayed on the PDU screen.
Checks of the download will be performed but will be displayed only if an error occurs.
While the download is in progress the message, ‘Download in progress. Do NOT touch
PDU/MPA or vehicle’, is displayed. Disregard any failure messages that may display on
the instrument pack.
REINSTALL FUEL PUMP RELAY SCREEN
ILLUSTRATION 10
14. The application then indicates that the fuel pump relay BTFR04 must be reinstalled
(Illustration 10).
After reinstalling the fuel pump relay, select the check icon to continue.
Date of issue 11/99 Amended 04/01
Bulletin Number 303-35 Page 9 of 15
REINSTALL FAN MODULE FUSE SCREEN
ILLUSTRATION 11
15. The application then indicates that fuse for the radiator fan module (EMF012 for XK8,
EMF014 for V8 XJ Series) must be reinstalled (Illustration 11).
After reinstalling the fuse for the radiator fan module, select the check icon to continue. At
this time PECUS E may display on the instrument pack. Disregard the message.
DATE ENTRY SCREEN SCREEN
ILLUSTRATION 12
16. Once the download is completed and verified, insert the date (Illustration 12), which must
be entered in the Federal format, MM/DD/YYYY, using the full four figure year input (such
as April 2, 1999 = 04/02/1999).
17. The date together with the VIN number and the old and the new flash version numbers, read
from the ECM, must be printed out and retained in the vehicle file. Connect the PDU to the
multimedia PC as instructed. (The PC must have the PDU-PC Version 3.2 (JTP 628/2) or
later software installed. Refer to Administration Bulletins.) Print the trace from the
Multimedia PC. Then reconnect the PDU to the MPA and the vehicle as instructed.
Page 10 of 15
Bulletin Number 303-35
Date of issue 11/99 Amended 04/01
MODIFICATION LABEL (ALL VEHICLES INCLUDING CALIFORNIA)
WRITE IN D
ATE
DA
WRITE IN DEALER NUMBER
ILLUSTRATION 13
18. The display will warn the user that the MPA/PDU is about to drive the engine cooling fan.
Select the check icon to continue. Check if the fan is operating.
19. The user will then be offered the ‘YES/NO’ option.
If the ‘NO’ option is selected the power to the fan will be switched off . An instruction to
check that the fuse is installed and functional will be displayed. The PDU will then return
to the previous stage to check the fan.
If the ‘NO’ option is selected a second time the user will then be prompted to run the
‘Engine Management Diagnostics’ routine.
If the ‘YES’ option is selected this will turn off the fan and exit the process.
20. On XK8 vehicles, reinstall KTM fuse 6, if it was removed earlier in step 4.
21. The display will ask ‘Does engine start?’ to instruct the user to start the engine to confirm
the installation of the fuel pump relay.
22. After a successful flash reprogramming the message, ‘Please ensure the new emissions
label is affixed to the vehicle’, is displayed. Select the check icon to complete the process.
Enter the dealer number and date and apply the label over a S 819 or S471 sticker if present,
(Illustration 13, part no. S 479 STK) to the driver side B post below the door striker plate on
XK8 vehicles, and next to the left hood hinge on V8 XJ Series. Be sure to apply the clear
protective sheet over the label. On 1997 MY XK8 vehicles, do not cover the S831 sticker.
California Dealers: Fill out and place the salmon colored “Vehicle Emission Recall - Proof
of Correction” form (Illustration 14, part no. S CAL RCL) in the vehicle glove
compartment.
23. The application will then return to the Main Menu.
PROOF OF CORRECTION FORM (CALIFORNIA ONLY)
ILLUSTRATION 14
Date of issue 11/99 Amended 04/01
Bulletin Number 303-35 Page 11 of 15
ERROR HANDLING
•
A process that has failed is repeated twice before the application advises the user that there
has been an error.
•
The message, ‘An error has occurred’, will be displayed. Select the check icon to proceed.
•
Instructions for the correction of errors and the installation of the fuses and/or relays will be
displayed.
ERROR PROCEDURES
Error Me ssage
De scription
Re cove ry Proce dure
Corrupt me ssage
re ce ive d
Indicates that either a bad
digit or a bad message has
been received
Check the connector, run the MPA, PDU
and engine diagnostics before rerunning
the procedure
Se curity e rror
Indicates that either security Contact Jaguar Technical Hotline at 1(888)
access is required or has
JAG-DLRS
been denied
Module comms.
e rror
Indicates that no reply was
received from the module
Check connector and retry. If this error
occurs again run MPA, PDU and Engine
Diagnostics before rerunning the procedure
Ge ne ral e rror
Indicates an error not
described in this table
Run MPA, PDU and Engine Diagnostics
before rerunning the procedure. If this
error occurs again contact Jaguar
Technical Hotline at 1(888) JAG-DLRS
MPA e rror
Indicates that a fault has
occurred with the MPA
Run MPA self test diagnostic
Download numbe r
e xce e de d
Indicates that the maximum
number of downloads has
been exceeded
Contact Jaguar Technical Hotline at 1(888)
JAG-DLRS
Page 12 of 15
Bulletin Number 303-35
Date of issue 11/99 Amended 04/01
ERROR MESSAGE ON
PDU SCREEN
Code 12
(Not illustrated. Similar to
above).
STAGE
ACTION
When this screen is
displayed after stage 12,
code 3D 9 indicates that the
wrong relay was removed
at step 10 or the wrong fuse
at step 11.
Self-rectification procedure
will begin. Wait and then
follow the displayed
instructions.
If displayed at step 14,
code 3D 6 indicates that the
KTM has not been
disconnected or disabled at
step 4A or 4B (where
applicable).
Self-rectification procedure
will begin. Wait and then
follow the displayed
instructions.
Appears when
reprogramming has been
attempted 3 times without
success.
Contact Jaguar Technical
Hotline 1(888)JAG-DLRS
Code 12 appears if the
ignition is left 'ON' during
the Reprogramming
process.
Parts Information:
DESCRIPTION
S 479 Modification Sticker
California Vehicle Emission Recall Proof of Correction form (salmon color)
Date of issue 11/99 Amended 04/01
PART NUMBER
S 479 STK
S CAL RCL
Bulletin Number 303-35 Page 13 of 15
Warranty Information:
Note: Service Actions S819 and S471 are now closed.
Service Action S479 does not apply to supercharged vehicles.
Service Action S479
VEHICLE
R.O.
NUMBER
DESCRIPTION
ALLOWANCE
TIME
1997-98 MY
RP
XK8
VIN 001036020733
1999 MY XK8
VIN 031303042775
Model codes 2830,
2840
1998 MY
V8 XJ Series
VIN 812256819771
1999 MY
V8 XJ Series
VIN 853936878717
Model codes 2811,
2851, 2853
18.91.22
Reprogram ECM and apply label
1.05 hrs.
1997-98 MY
RR
XK8
VIN 001036020733
1999 MY XK8
VIN 031303042775
Model codes 2830,
2840
1998 MY
V8 XJ Series
VIN 812256819771
1999 MY
V8 XJ Series
VIN 853936878717
Model codes 2811,
2851, 2853
18.91.22
10.10.10
Reprogram ECM and apply label
Drive in/Drive out time
1.05 hrs.
0.15 hrs.
Page 14 of 15
SUMMARY
CODE
Bulletin Number 303-35
Date of issue 11/99 Amended 04/01
Note: Always perform a DCS claims 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 S471 or S819 appears in the fault code field, proceed as follows:
1. On vehicles which have not been previously reprogramming to S819 or
S471, perform S479 at the next service opportunity, or as soon as can be
arranged in case of a customer complaint.
2. On vehicles previously reprogramming to S819, but not reprogramming to
S471 condition, perform S479 on all affected vehicles at the next service
opportunity, or as soon as can be arranged in case of a customer complaint.
3. On vehicles previously reprogrammed to S471, perform S479 on a
customer complaint basis ONLY in the case of additional cold start
complaints.
4. On vehicles previously reprogrammed to S819 and S471, S479 should be
performed on a customer complaint basis only.
5. On 1999 MY vehicles, S479 should be performed on a customer
complaint basis only (since they already are at the S471 software level).
If S479 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-1
warranty claim form.
Date of issue 11/99 Amended 04/01
Bulletin Number 303-35 Page 15 of 15
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