Page 1092 of 2490
Engine Ignition - Spark
Plugs
Re
mo
val and Installation
Remov
a
l
Installation
1.
Disc onne
ct battery ground cable (IMPORTANT, see SRO
86.15.19 for further information).
2. Remove air intake tube / meter / air cleaner cover for access;
refer to 19.10.30.
3. Remove ignition coils; refer to 18.20.41 (bank 1) and 18.20.42
(bank 2).
4. Re
move spark plugs.
5. Clean all components as necessary.
1. Installation
is a reversal
of the removal procedure.
Check ele
ctrode gap is to the
correct specification. Refer
to the Specification Section and current Service Bulletins.
Apply su
itable lubricant e.
g. Neverseez Compound, to
lower four threads of spark plug(s) adjacent to the
electrodes.
The lubrican t must be applied
to full thread depth for at
least 180° of the thread circumference.
T h
e electrodes must not be
contaminated during this
process.
2.
Page 1096 of 2490

RE
PAIR the circuit between the EGR valve and battery. This circuit includes the EMS relay and the
EMS fuse box. For additional info rmation, refer to the wiring diagrams. CLEAR the DTC. TEST the
system for normal operation.
No GO to A2
.
A2: CHECK THE EGR VALVE COIL WIND
INGS FOR CONTINUITY
Meas
ure t
he resistance between pins 04 and 06 of the EGR valve.
1
Meas
ure t
he resistance between pins 01 and 03 of the EGR valve.
2
Is either resi
stance
greater
than 80 ohms?
Yes INSTALL a new EGR valve.
REFER to Exhaust Gas Recirculation (EGR) Valve
- in thi
s section.
CLEAR the DTC. TEST the syst em for normal operation.
No GO to A3
.
A3: CHECK THE EGR VALVE COIL WINDINGS TO
POWER SUPPLY CIRCUIT FOR CONTINUITY
Meas
ure t
he resistance between pins 02 and 03 of the EGR valve.
1
Meas
ure t
he resistance between pins 05 and 06 of the EGR valve.
2
Is either resi
stance greater
than 80 ohms?
Yes INSTALL a new EGR valve.
REFER to Exhaust Gas Recirculation (EGR) Valve
- in thi
s section.
CLEAR the DTC. TEST the syst em for normal operation.
No GO to A4
.
A4: CHECK THE EGR VALVE T
O ECM
CIRCUITS FOR HIGH RESISTANCE
Disc
onnect the battery negative terminal.
Vehicles with AJ26 engine:
D i
sconnect the ECM electrical connector, EM12
Meas
ure t
he resistance between the following:
PI34, pin
0
4 (YU) and EM12, pin 01 (YU)
PI34,
pi
n 01 (YG) and EM12, pin 02 (YG)
PI34, pin
0
6 (YN) and EM12, pin 03 (YN)
PI34,
pi
n 03 (YR) and EM12, pin 04 (YR)
Vehicles with AJ27 engine:
D i
sconnect the ECM electrical connector, EM85
Meas
ure t
he resistance between the following:
PI34, pin
0
4 (YU) and EM85, pin 03 (YU)
PI34, pi
n 01 (YG) and EM85, pin 04 (YG)
PI34, pi
n 06 (YR) and EM85, pin 09 (YR)
PI34, pi
n 03 (YR) and EM85, pin 10 (YR)
1
Are an
y of the resistances greater than 5 ohms?
Yes REPAIR the high resistance circui t. For additional information, refer to the wiring diagrams. CLEAR
the DTC. TEST the system for normal operation.
No GO to A5
.
A5: CHECK THE EGR VALVE T
O ECM CIRCUITS FOR SHORT TO HIGH VOLTAGE
R
e
connect the battery negative terminal.
1
Meas
ure t
he voltage between the following:
PI34, pin
0
4 (YU) and GROUND
PI34, pin
0
1 (YG) and GROUND
PI34, pin
0
6 (YN) and GROUND
PI34, pin
0
3 (YR) and GROUND
2
Are any of th
e volt
ages greater than 3 volts?
Yes REPAIR the short circuit. For addi tional information, refer to the wiring diagrams. CLEAR the DTC.
TEST the system for normal operation.
No
Page 1120 of 2490

Intake Air Distribution and Filtering - Charge Air Cooler LH
Remo
val and Installation
Remov
a
l
Installation
1. Disc onne
ct battery ground cable (IMPORTANT, see SRO
86.15.19 for further information).
2. Drain radiator coolant; refer to 26.10.01.
3. Remove air cleaner cover / intake assembly; refer to 19.10.30.
4. Remove throttle body; refer to 19.70.04.
5. Remove exhaust gas re-circulation valve (EGR) if installed;
refer to 17.45.01.
6. Remove throttle intake elbo w; refer to (SC) 19.70.28.
7. Remove supercharger outlet duct; refer to 18.50.16.
8. Remove coolant outlet pipe; refe r to operation (SC) 26.31.08.
9. Remove supercharger drive belt; refer to 18.50.08.
10. Remove supercharger; refer to operation 18.50.15.
11. Detach engine harness retaining clip from rear of charge air
cooler.
12. Di
sconnect hoses from charge air cooler.
Pla
ce absorbent cloth in appropriate position.
Di
sc
onnect hoses.
13 .
CAUTI
ON: Take care to avoi
d dropping any objects or
foreign matter into engine inle t duct with charge air cooler
removed.
Remove charge air cooler from the engine.
1. Remove eight bolts.
Remove charge air cooler.
2
. Discard gasket.
Cle
a
n all mating faces.
1.
Install ch
arge air
cooler to adaptor.
1. Install new gasket.
2. Install charge air cooler.
Page 1121 of 2490
2.
Conne
ct hoses to charge air cooler.
Conne
ct hoses.
3. Install supercharger; refer to 18.50.15.
4. Install supercharger driv e belt; refer to 18.50.08.
5. Install engine coolant outlet pipe; refer to 26.31.08.
6. Install supercharger outlet du ct and new gasket; refer to
18.50.16.
7. Install throttle intake elbow; refer to 19.70.28.
8. Install exhaust gas re-circulation valve (EGR) if applicable;
refer to 17.45.01.
9. Install throttle body ; refer to 19.70.04.
10. Install air cleaner cover / intake assembly; re fer to 19.10.30.
11. Refill cooling system; refer to (SC) (26.10.01).
12. Reconnect battery ground cable (IMPORTANT, see SRO
86.15.15 for further information).
Page 1122 of 2490

Intake Air Distribution and Filtering - Charge Air Cooler RH
Remo
val and Installation
Remov
a
l
Installation
1. Disc onne
ct battery ground cable (IMPORTANT, see SRO
86.15.19 for further information).
2. Drain radiator coolant; refer to 26.10.01.
3. Remove air cleaner cover / intake assembly; refer to 19.10.30.
4. Remove throttle body; refer to 19.70.04.
5. Remove exhaust gas re-circulation valve (EGR) if installed;
refer to 17.45.01.
6. Remove throttle intake elbo w; refer to (SC) 19.70.28.
7. Remove supercharger outlet duct; refer to 18.50.16.
8. Remove coolant outlet pipe; refe r to operation (SC) 26.31.08.
9. Remove supercharger drive belt; refer to 18.50.08.
10. Remove supercharger; refer to operation 18.50.15.
11. Remove intake air temperatur e sensor 2 from charge air
cooler; refer to 18.30.52.
12. Detach engine harness retaining clip from rear of charge air
cooler.
13. Di
sconnect hoses from charge air cooler.
Pla
ce absorbent cloth in appropriate position.
Di
sc
onnect hoses.
14 . CAUTI
ON: Take care to avoi
d dropping any objects or
foreign matter into engine inle t duct with charge air cooler
removed.
Remove charge air cooler from the engine. 1. Remove eight bolts.
Remove charge air cooler.
2
. Discard gasket.
Cle
a
n all mating faces.
1.
Install ch arge air
cooler to adaptor.
1. Install new gasket.
2. Install charge air cooler.
Page 1123 of 2490
2.
Conne
ct hoses to charge air cooler.
Conne
ct hoses.
3. Install intake air te mperature sensor 2 to charge air cooler;
refer to 18.30.52.
4. Install supercharger; refer to 18.50.15.
5. Install supercharger driv e belt; refer to 18.50.08.
6. Install engine coolant outlet pipe; refer to 26.31.08.
7. Install supercharger outlet du ct and new gasket; refer to
18.50.16.
8. Install throttle intake elbow; refer to 19.70.28.
9. Install exhaust gas re-circulation valve (EGR) if applicable;
refer to 17.45.01.
10. Install throttle body; refer to 19.70.04.
11. Install air cleaner cover / intake assembly; re fer to 19.10.30.
12. Refill cooling system; refer to (SC) (26.10.01).
13. Reconnect battery ground cable (IMPORTANT, see SRO
86.15.15 for further information).
Page 1126 of 2490
Intake Air Distribution and Filtering - Charge Air Cooler Radiator
Remo
val and Installation
Remov
a
l
1.
Op
en the engine compartment and fit paintwork protection
sheets.
2. Disconnect the battery.
1. Remove the battery cover.
2. Disconnect the battery ground cable.
3. Remove the engine radiator and air conditioning condensor
assembly. Refer to operation 26.40.01.
4. Remove the grill assembly fo r access. Refer to operation
76.55.15.
5. Drain th e charge air cooler radiator.
Reach t
hrough the front bumper
splitter vane to remove
the radiator drain plug.
6. Disc
onnect the radiator
hoses from the radiator.
1. Disconnect the coolant pump to radiator hose.
2. Disconnect the return hose.
3. Disconnect the bleed pipe.
7. Re
move the two radiator fixing bolts.
8. Displace and re-position the am bient air temperature sensor
and bracket.
Page 1127 of 2490
I
nstallation
9.
Di
splace the radiator from
the top mounting rubbers.
1. Fit and seat the radiator to the top mounting rubbers.
2. F
it the two securing bolts.
Ensure that the ambient air
temperature sensor mounting bracket is secured by the
lefthand radiator bolt.
3. Re-connect the radiator feed ho se, return hose and bleed pipe.
Fit all hose spring clips.
4. Refill the radiator coolant. Refer to operation 26.10.01.
5. Fit the grill assembly. Refer to operation 76.55.15.
6. Fit the engine radiator and air conditioning condensor
assembly. Refer to operation 26.40.01.
7. Reconnect the battery. Refer to the battery reconnection
procedure in 86.15.15.
8. Remove the paintwork protection sheets and close the engine
cover.