Attachment III - Technical Information

OVERVIEW

This program involves testing and replacing the coil-on-plug assemblies, if needed.





A flow chart has been developed to help direct you to the proper repair. See Figure 1.

STEP 1: CHECK FOR DTCS AND MODE 6 DATA

1. Connect the Vehicle Communication Module (VCM) to the vehicle and the Integrated Diagnostic System (IDS). Check for DTCs related to cylinder misfire.

2. Check Mode 6 data for cylinder misfire data.

STEP 2: IDENTIFY AFFECTED CYLINDER(S)

1. Using data obtained in Step 1,identify each cylinder that has misfire data.

STEP 3: COIL STRESS TEST

NOTE:
The Coil Stress Test should be performed on the coils that were identified in Step 2.

1. Connect the Vehicle Measurement Module (\,MM) to the vehicle and the IDS.

2. Remove the engine appearance cover.

3. Remove the air cleaner outlet tube.

4. Remove the ignition coil cover bolts and cover.

5. Remove the identified coil-on-plug from the spark plug. Turn it upside down so it will not spark to ground during the test.

6. Connect the coil-on-plug clip to the coil-on-plug and connect the other end of the VMM secondary ignition transducer cable to the VMM.

7. Disconnect the fuel injector electrical connector from the cylinder being tested so raw fuel is not washing the cylinder.





8. Start the vehicle and the scan oscilloscope. Record the data. Refer to Figure 2 showing the difference between a good coil pattern and defective coil patterns.

9. Turn the vehicle off.

10. Reconnect the fuel injector electrical connector.

11. Remove the coil-on-plug clip from the coil-on-plug.

12. If the coil is defective, install a new coil-on-plug assembly.

^ Disconnect the coil-on-plug assembly electrical connector and remove the coil-on-plug assembly.

^ Apply a light coat of dielectric compound XG-3-A or equivalent, to the inside of the new ignition coil boot. Install new coil-on-plug assembly and connect the electrical connector.

13. Repeat Steps 5 through 12 on the remaining cylinders identified in Step 2.

NOTE:
If any more than 2 coils are defective, call the Special Support Service Center (SSSC) for prior approval.

14. Clear diagnostic trouble codes.

STEP 4: REPLACE COIL-ON-PLUG COVER ASSEMBLIES





1. Apply a bead of RTV silicone sealant to the lower corner of the ignition coil cover. See Figure 3.

2. Install the ignition coil cover and tighten the bolts to 10 Nm (89 lb-in).

3. Install the air cleaner outlet tube.

4. Install the engine appearance cover.