XJR and VDP Supercharged Vehicles

1. Open hood and install fender protectors.

2. Open luggage compartment lid and remove battery cover.

3. Disconnect battery.

Note:
Ensure the radio code is available before disconnecting the battery.





4. Remove air intake tube/mass air flow sensor/air cleaner cover assembly (see Illustration 1).

5. Remove left and right hand false bulkhead top covers and engine compartment rear cover (see Workshop Manual, JTIS CD ROM: section; 501-02).





6. Disconnect evaporative emissions (EVAP) canister purge valve electrical connector (see Illustration 2).





7. Remove the EVAP canister purge valve securing screws (see Illustration 3).

8. Displace EVAP canister purge valve for access.





9. Remove EGR transfer pipe to EGR valve securing screws (see Illustration 4).

10. Reposition EGR transfer pipe for access to the gasket.

11. Remove and discard EGR transfer pipe to EGR valve gasket.





12. Remove EGR transfer pipe to right hand exhaust manifold securing nuts (see Illustration 5).

13. Displace and remove EGR transfer pipe from the right hand exhaust manifold studs.

14. Remove gasket from the right hand exhaust manifold studs.

15. Clean the relevant components and mating faces.

16. Install a new gasket to the right hand exhaust manifold studs.

17. Install EGR transfer pipe to the right hand exhaust manifold studs.





18. Install, but do not fully tighten, EGR transfer pipe to right hand exhaust manifold securing nuts (see Illustration 6).

19. Adjust EGR transfer pipe (via convolutions) to align with the EGR valve.

20. Install a new gasket between the EGR transfer pipe flange and the EGR valve.

21. While maintaining the gasket in position, align the EGR transfer pipe flange to the EGR valve.





22. Install and tighten EGR transfer pipe to EGR valve securing screws to 21 Nm (see Illustration 7).





23. Final tighten EGR transfer pipe to right hand exhaust manifold securing nuts to 21 Nm (see Illustration 8).

24. Align EVAP canister purge valve to mounting position.





25. Install and fully tighten EVAP canister purge valve securing screws to 6 Nm (see Illustration 9).





26. Connect EVAP canister purge valve electrical connector (see Illustration 10).

27. Install left and right hand false bulkhead top covers and engine compartment rear cover (see Workshop Manual, JTIS CD ROM, section: 501-02).

28. Re-fill cooling system to the correct level.

29. Install cooling system expansion tank pressure cap.

30. Check accelerator cable adjustment.





31. Install air intake/mass air flow sensor/air cleaner cover assembly (see Illustration 11).

32. Connect battery.

33. Re-align battery cover and close luggage compartment lid.

34. Remove fender protectors and close hood.