My 2003 XKR engine warning light is on and comes on again after being manually reset and driven for a while. Car runs just fine.

However it won't pass inspection in NY. The inspection station gets a 400 code indicative of an Exhaust Gas Recirculation Valve problem. Nearest Jag dealer is two hours away; a real pain to leave the car, rent another & return days later. Also expensive.

I can buy a new valve from Jag for $300+ and have it installed (I presume) locally.

All suggestions gratefully received. Thanks!

 

I just went through this a few weeks ago, car also ran fine except for the P0400 and CEL light coming on. I ordered a new EGR valve + gaskets.

When I tore it down I found the EGR tube was cracked. It looks like an aluminum pressed piece with a ribbed elbow (connecting the EGR through the tube to the passenger side header), and the ribbed elbow was cracked. I ordered a new tube (I found the britishparts site ships fast, uses OEM jag parts, and is pretty cheap) but this cause a bit more down time. Also ordered new gaskets (header->egr tube, EGR tube->egr valve, EGR valve->TB, and TB gasket).

Although the EGR valve looked good and possibly the tube could have been the only culprit I changed it anyways, since I didnt want to go back in there again.

All together a very DIY-able job, just take the intake tube off, 4 bolts for the throttle body, and you can get back there no problem. With all the parts handy you can probably get it done in one night. There is a Jag TSB bulletin for changing the EGR tube that you could google that lists exact directions and torque specs, seems like a common issue. Good luck!

 

As with most devices on these cars, the problem could also be a weak electrical connection. Before you spend real money and time on the problem, I suggest unplugging the EGR connector, spraying both sides clean with CRC Electronic Parts Cleaner, and plugging / unplugging / plugging a few times to scrape the prongs clean.

It's 50 / 50 that this will help...worth a try, in my opinion.

 

The 4.0L XKR EGR tube failure is a Jaguar documented problem...here is the TSB on it:

https://www.jaguarforums.com/forum/a...r-tube-tsb-pdf


For a 2003 4.2L however, I think it was resolved.

 

Thanks all. Very useful input. Will proceed accordingly.
Best,

Rider in NY

 

Thanks again, all. Here is what happened.
Before I had a chance do to anything the engine warning light went off for a couple of days. I took the XKR to an inspection station and it passed!

Next day the light went back on. Stayed on for a day. Then off... just after I 'floored' the car to escape an undesirable situation that presented it self as I entered an interstate highway. Went from maybe 30-35 to 95 with pedal to the metal. Then continued 10 miles at 75-90 before I noticed that the light had gone out again. That was this morning. No idea if this is a coincidence or if the car really needs to be driven hard every so often.

Any ideas, comments?

Thanks again.

Rider

 

The (in)famous Italian tune up!

At least you have the inspection behind you, I'd drive it for a week or so and get the codes checked again if the light doesn't show up again.

 

My EGR codes would be sporatic as well. Even once the system completed its check with the proper "ready" P0100 code (I think that's what the number is) I'd still get the P0400 egr code after a few days (+- lean and or rich codes). You think it'll go away...but it wont

My money would still be on the valve and/or the tube. The valve also gets plugged and I have heard of people rebuilding them successfully.

Good luck!

 

hey, by chance, did either of you experience any foul smelling sulfur during hard acceleration prior to the bad egr or leaking tube?

 

I don't recall so, but I also have a coupe, so I don't usually smell anything other than the periodically conditioned leather

But seriously, I dont think the broken EGR tube gave any noticeable signs other than the mysterious EGR and lean codes popping up. It's so well tucked in the back by the firewall too, I don't think there's any easy way of checking it from the outside. You have to take the TB off just to get to it, and even then smaller hands help!

 

Nope, no smells. Blasted light has come on again but at least now the car is inspected.
I have a vague sense that conditions of extreme humidity cause the englne light to go out which makes me think that I have an electrical connection issue.

 

I used to have those thoughts too, but in the end that's just reaching. Thing is, codes need to come up 2 consecutive cycles to light up the CEL. I have a feeling that short commutes don't register as a full "cycle", either. I believe there are some specific conditions to engage the EGR as well, so that's probably why my codes kept coming and going sporadically. Either way, my only advice would be get it fixed, because hoping that it'll magically disappear just won't happen. Good luck!

 

that's the CAT converters doing their job.