EGR - Pipe Leakage, Replacement, Parts, Warranty
NO.: TSB-94-15-001DATE: March, 1994
MODEL: 1991-92 3000GT, 1992 Diamante
SUBJECT:
INSTRUCTIONS FOR REPLACING EGR PIPE
(USE LATEST PARTS ONLY)
BACKGROUND INFORMATION
On some 1991-92 3000GTs and 1992 Diamantes (California vehicles only), replacement of the EGR (Exhaust Gas Recirculation) pipe is necessary if the pipe develops a leak or if one of the pipe clamps is broken. EGR pipe leakage can occur if the clamp securing the pipe is not installed correctly. When the clamp is incorrectly installed, the EGR pipe may vibrate during engine operation, causing leakage at the bellows area of the pipe and/or clamp breakage.
If the EGR pipe develops a leak or if the EGR pipe clamp is broken, replace the pipe assembly using the latest part numbers shown in this bulletin. There are two EGR pipe assemblies, one for vehicles with TCL (Traction Control), the other for Non-TCL equipped vehicles.
The remainder of this bulletin provides affected vehicle information, EGR pipe identification, replacement instructions, parts information, and warranty information.
VEHICLES AFFECTED
1991-92 3000GT, DOHC Non-Turbo Engine, California vehicles only 1992 Diamante, DOHC Engine, California vehicles only
DESCRIPTION
When replacing the EGR pipe on affected vehicles, use the instructions shown below.
WARNING:
Observe standard shop safety practices while performing EGR pipe replacement.
NOTE:
Before installing a new EGR pipe, verify that the new pipe has two clamps. Also, note the differences between torsional angle (pipe bend) and upper clamp length for TCL and non-TCL equipped vehicles. With TCL, the pipe's torsional angle is less than the non-TCL pipe, and the upper clamp length is 44.6 mm. Without TCL, the pipe's torsional angle is greater than the TCL pipe, and the upper clamp length is 34.3 mm.
1. Remove the clamp bolt(s) securing the EGR pipe to the intake manifold surge tank bracket. Save the bolt(s) for re-use. Depending on vehicle production date, the EGR pipe is secured with either one or two clamps.
2. Loosen the two flare nuts attaching each end of the EGR pipe. If necessary, apply penetrating oil to help loosen the nuts. Remove the EGR pipe and clamps(s).
3. Obtain a new EGR pipe. For TCL-equipped vehicles, use part number MD194820. For non-TCL equipped vehicles, use part number MD194819.
4. If the old EGR pipe had only one upper clamp, remove the intake manifold surge tank bracket bolt located underneath the clamp. This bolt will be used to secure the lower clamp on the new EGR pipe.
5. Reinstall the EGR pipe and hand-tighten the flare nuts on each end.
6. Install the upper and lower EGR pipe clamp bolts. (These bolts also secure the surge tank bracket to the intake manifold.) Torque the bolts 18 N-m (13 ft.lbs.).
7. Carefully tighten the two flare nuts, making sure not to deform the EGR pipe. Torque the flare nuts 60 N-m (43 ft.lbs.).
8. Start the engine to verify there is no leakage from the EGR pipe.
PARTS INFORMATION
Replacement EGR pipes are available from your facing PDC. Part numbers are:
Do not use any other parts numbers when replacing the EGR pipe on affected vehicles.
WARRANTY INFORMATION
Labor Operation: 17331000 Position Code: 173310
Time Allowance: Actual time. PWA required for time in excess of 0.4 hrs.
Coverage: 5 year/50K miles
Use normal warranty procedures.