TREZIA INTERCOOLER / ENGINE CONTROL ECM REPLACEMENT

1

TREZIA

INTERCOOLER / ENGINE CONTROL ECM REPLACEMENT

Jan. 13, 2015.

Fuji Heavy Industries Ltd. Quality Assurance Dept.

1. OPERATION FLOW CHART --------------------------------- 3 2. IDENTIFICATION OF AFFECTED VEHICLES ---------- 4 3. PREPARATION -------------------------------------------------- 5 4. WORK PROCEDURE ------------------------------------------- 8

TECHNICAL INSTRUCTIONS

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Safety Precautions

Be sure to observe the following precautions to prevent accidents and injuries.

- Park the vehicle and chock the wheels.

- If it is necessary to start the engine, perform the operation in a well ventilated area.

- Before removing and reinstalling heavy parts such as the engine, transmission and differential using specified tools, check that there are no problems with the tools.

- When working in a group of 2 or more, each person must work to ensure the safety of all team

members.

- To prevent burns and other injuries, use extra caution when handling parts that are subject to high temperatures, as well as rotating, sliding, or vibrating parts.

- When lifting the vehicle using a jack, support it in the specified location using a safety stand.

- When lifting the vehicle using a lift, lock the lift for safety. Also perform the following operation with care.

Use of auto lift - Make absolutely certain that there are no other workers and no tools, parts, or other objects

within the movable range of the lift. Also, be sure to announce all lift operations out loud (such as “Raising the lift!” and “Lowering the lift!”) to alert other workers.

- When raising or lowering the lift, pay attention to the positions of your arms, legs, and other body

parts, and be extremely careful to prevent them from being caught in the lift. Use of brake cleaner

- Use brake cleaner for appropriate purposes in accordance with instructions in the manual.

- Do not use brake cleaner to remove dirt or stains from the engineer clothes and so forth, as it can catch on fire and cause serious burns.

< Precautions >

- Do not use brake cleaner near flames or fire.

- Do not use large amounts of brake cleaner in a room where a fire is burning.

- Do not keep brake cleaner in a place subject to high temperatures exceeding 40°C, such as a place subject to direct sunlight or near fire.

- Do not put brake cleaner in fire.

Edges

- When handling the edges of parts and panels, wear protective gloves or apply protective tape to the edges to prevent injuries to your hands and fingers.

3

1. OPERATION FLOW CHART

Check whether or not the vehicle has the affected vehicle VIN number.

Finish No

Yes

Affected items ・ Intercooler ・ ECM

Affected item ・ ECM

Inspect the affected item(s). (For details, refer to the respective work procedures in this document)

Conduct the work procedure(s) in accordance with the inspection result(s).

Return the vehicle to the original state and finish the work.

Pattern 1 Pattern 2

4

2. IDENTIFICATION OF AFFECTED VEHICLES 2.1. COVERED VIN RANGE

From To # of vehicles JTDKC3C3#06000004 - JTDKC3C3#06003666 3,646 Notes:

# indicates that various characters may occupy that position. Not all vehicles in these VIN range, are affected and/or sold in your country. For the detailed list of concerned vehicles, please refer to the affected VIN list.

2.2. VEHICLE IDENTIFICATION NUMBER LOCATION

VEHICLE IDENTIFICATION NUMBER (a) The vehicle identification number is stamped on the vehicle identification number plate and name plate as shown in the illustrations. A: Vehicle Identification Number Plate B: Name Plate

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3. PREPARATION 3.1. Replacement components

Parts:

<For MT> Part Name Part No. Qty Remarks

INTERCOOLER ASSY 04004-2850N 1 BRACKET 82715-0DF20 1 INTERCOOLER KIT 04004-43233 1

CUSHION, RADIATOR SUPPORT 16523-21030 1 HOSE, AIR, NO.1 17341-33080 1 HOSE, AIR, NO.2 17342-33051 1 HOSE, AIR, NO.3 17343-33150 1 TUBE, AIR, NO.2 17362-33090 1 CONNECTOR, INTAKE AIR 17861-33080 1 GASKET, EGR VALVE 25627-33010 1 GASKET, EGR INLET 25628-33040 1 GASKET, EGR PIPE (GASKET PIPE) 25634-33010 1

GASKET, VENTURI (GASKET DIESEL THROTTLE) 26171-33030 1

GASKET, INTAKE AIR CONNECTOR(GASKET DIESEL THROTTLE) 26171-33050 1

WIRE, ENGINE, NO.4 82124-52040 1 BOLT 91671-80816 1 GASKET 90430-16010 1 CLAMP, HOSE 90460-50005 4 CLAMP, HOSE 90460-63011 2 GROMMET 90480-22025 2 BOLT, FLANGE 91551-80850 2 BOLT, WITH WASHER 91671-80614 1

BOLT, WASHER BASED 90105-08438 2 This part is not needed.

Please scrap it.

ENGINE CONTROL ECM (ECU) 89660-5C630 1

SEAL, FR FENDER TO C 53868-52050 1 Prod. Date:

Before July 31, 2012.



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<For MMT>

Part Name Part No. Qty Remarks INTERCOOLER ASSY 04004-2850N 1 BRACKET 82715-0DF20 1 INTERCOOLER KIT 04004-43633 1

CUSHION, RADIATOR SUPPORT 16523-21030 1 HOSE, AIR, NO.1 17341-33080 1 HOSE, AIR, NO.2 17342-33051 1 HOSE, AIR, NO.3 17343-33150 1 TUBE, AIR, NO.2 17362-33090 1 CONNECTOR, INTAKE AIR 17861-33080 1 GASKET, EGR VALVE 25627-33010 1 GASKET, EGR INLET 25628-33040 1 GASKET, EGR PIPE (GASKET PIPE) 25634-33010 1

GASKET, VENTURI (GASKET DIESEL THROTTLE) 26171-33030 1

GASKET, INTAKE AIR CONNECTOR(GASKET DIESEL THROTTLE) 26171-33050 1

WIRE, ENGINE, NO.4 82124-52040 1 GASKET 90430-16010 1 CLAMP, HOSE 90460-50005 4 CLAMP, HOSE 90460-63011 2 GROMMET 90480-22025 2 BOLT, FLANGE 91551-80850 2 BOLT, WITH WASHER 91671-80614 1

BOLT, WASHER BASED 90105-08438 2 This part is not needed. Please scrap it.

ENGINE CONTROL ECM (ECU) 89660-5C640 1 Prod. Date:

Nov. 2011 - Jan. 2013

ENGINE CONTROL ECM (ECU) 89660-52Y50 1 Prod. Date:

Jan. 2013 - May. 2014






After Aug. 1, 2012.


After Aug. 1, 2012.

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3.2. Intercooler Replacement

Tools: Illustration Part Name Part No. Qty Remarks

- Subaru Select Monitor 3 - 1 For checking DTC

O2 Sensor Wrench 09224-00010 1 For tightening the intake

air temp. sensor

- Torque Wrench - - For checking tightening torque

Terminal Extraction Tool 09990-99010 1 For removing connector terminals

Equipment:

Part Name Part No. Qty Remarks Protective Gloves - 1 - Packing Tape - - Appropriate quantity Cloth - - Appropriate quantity Rope - - Appropriate quantity

Vise - 1 For clamping the intake air connector and No.2 air tube

Pieces of Wood - - Appropriate quantity Marker Pen - - Appropriate quantity Adhesive 1324 or Equivalent - Appropriate quantity

Diagonal Pliers or Similar Tools - 1 For cutting off the rib of the fan shroud

Protective Materials (e.g. Cardboard) - Appropriate quantity Marker Pen - - Appropriate quantity

3.3. Engine Control ECM Replacement

Tool: Illustration Part Name Part No. Qty Remarks

- Torque Wrench - - For checking tightening torque

- Subaru Select Monitor III - 1 For Learning Values Save and Write

Equipment:

Part Name Part No. Qty Remarks Protective Gloves - 1 - Protective Tape - - Appropriate quantity Cloth - - Appropriate quantity Rope - - Appropriate quantity Marker Pen - - Appropriate quantity Double ‒ Sided Tape - - Appropriate quantity

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4. WORK PROCEDURE

<TABLE OF CONTENTS>

A. WORK OUTLINE .........................................................................................................9 B. PRECAUTIONS FOR ALL OPERATIONS...................................................................9 C. WORK CONFIRMATION AND PREPARATION ........................................................12 D. INSPECTION OF INTERCOOLER.............................................................................14 E. REPLACEMENT OF INTERCOOLER

(ONLY WHEN INSPECTION RESULT IS NOT GOOD) ...........................................15 F. REPRACEMENT OF ENGINE CONTROL ECM........................................................58 G. VEHICLE RESTORATION .........................................................................................75

H. FINAL CHECKS BEFORE COMPLETION OF WORK..............................................77

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A. WORK OUTLINE

1. Refer to the VIN List to see if the vehicle’s VIN is applicable and find what to do. 2. Inspect the intercooler, and replace it with new one if required. 3. Replace the engine control ECM with new one.

B. PRECAUTIONS FOR ALL OPERATIONS

1. PRECAUTIONS WHEN RAISING VEHICLE USING A LIFT OR JACK

(a) Refer to the respective repair manual and follow the instructions within the Introduction section to ensure safety when working.

(b) Ensure the safety of all personnel near the lift or jack, including yourself, before beginning work. Also announce all lift and jack operations out loud to prevent any personnel from being caught or harmed in any way.

2. WEAR PROTECTIVE GLASSES (a) Wear protective glasses when working under

the vehicle or where there is any risk of flying parts or debris.

3. DO NOT USE BRAKE CLEANER AS STAIN REMOVER

(a) Do not spray brake cleaner onto any clothes since it is a flammable solvent that vaporizes easily. Do not use it near cigarettes or stoves as this can cause serious burns and injuries.

No Good

10

4. AVOID BURNS (a) If the engine is hot, wear protective gloves to

prevent burns.

5. VEHICLE PROTECTION (a) A fender cover, a grill cover, seat covers tape

etc. must be used to protect the vehicle from dirt or scratches.

NOTE: The protective measures listed above may not be shown in some illustrations to allow easy identification of the work location and to make the illustrations simple and easy to read.

6. HANDLING OF REMOVED PARTS (a) Destroy or mark and then store removed parts

in a separate container so as to not be assembled again in error.

(b) Check the removed parts when performing the completion inspection.

NOTE: The parts shown in the illustration to the left are examples only and differ from the actual replacement parts.

7. DO NOT BREAK PARTS WHEN WORKING INSIDE ENGINE COMPARTMENT

(a) Do not break parts by carelessly placing hands inside and leaning on the engine compartment while being preoccupied by work.

No Good

No Good

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8. CHECK INSIDE ENGINE COMPARTMENT BEFORE ENGINE START-UP

(a) Check that all necessary parts are installed. (b) Check that no tools or pieces of cloth are left

inside the engine compartment.

No Good

No Good

12

C. WORK CONFIRMATION AND PREPARATION

1. CONFIRM WHAT TO DO (a) Refer to the VIN LIST to see if the vehicle’s VIN is applicable and find what to do. (b) Strike out any check item(s) on the Check Sheet which are not applicable to

inspection.

Check item

VIN No. Intercooler Engine control ECM

JTDKC3C3#06 000004～

JTDKC3C3#06 002808

〇〇

JTDKC3C3#06 002809～

JTDKC3C3#06 003666

― 〇

# indicates that various characters may occupy that position. 〇：Inspection / replacement is necessary

―：Inspection / replacement is NOT necessary

2. CHECK FOR DTC(S) (a) If any DTC(s) have been set, check the DTC(s) and the freeze frame data, repair as

necessary, and then clear all DTC(s).

13

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D. INSPECTION OF INTERCOOLER

1. CHECK POSITION OF UPPER AIR HOSE (a) Check the position of the upper air hose. (b) Write down the check result onto the Check Sheet.

Result Air Hose Positions Action Required

NOT GOOD

Intercooler has to be replaced with a

new one

Intercooler does NOT have to be

replaced

15

E. REPLACEMENT OF INTERCOOLER (ONLY WHEN INSPECTION RESULT IS NOT GOOD)

1. The intercooler and intake air connector will be replaced with new ones. 2. The air hose between the diesel throttle body and intercooler and between the

turbocharger and intercooler will be changed to new ones.

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3. Since the rib of the fan shroud will interfere with the air hose due to change of the air horses, the rib will be cut off.

4. Using a terminal extraction tool (supplied), the wire terminals will be removed from the intake air temperature sensor connector. The removed wire terminals will be inserted into the connector of a new sub wire harness, and the sub wire harness will be connected to the vehicle wire harness.

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18

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20

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1. RECORD AUDIO AND AIR CONDITIONING SETTINGS

(a) When the battery cable is disconnected, the settings for the audio, air conditioning, etc., may be reset. Therefore, make a note of the settings before disconnecting the cable from the negative (-) battery terminal.

2. TAKE MEASURES AGAINST SECURITY OF THE NAVIGATION SYSTEM

(a) In some cases, a user password is set for restart of the system after disconnection of the power supply.

(b) Obtain confirmation of the customer in advance regarding conditions of the system at the time of returning the vehicle to the customer.

3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

CAUTION: For a vehicle with an HDD navigation system, disconnect the negative battery terminal 6 minutes after IG OFF to allow the memory processing of the navigation system to complete.

4. WEAR PROTECTIVE GLOVES

CAUTION: Wear protective gloves to prevent injuries.

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5. REMOVE No.1 ENGINE COVER

6. REMOVE AIR CLEANER CAP SUB-ASSEMBLY AND HOSE

(a) Disconnect the connector. (b) Unclamp the wire harness at the 4 locations. (c) Disengage the 2 air cleaner case clamps.

(d) Loosen the hose clamp, and disconnect the air cleaner cap and hose.

7. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

(a) Detach the air cleaner filter element. (b) Remove the 3 bolts, and detach the air cleaner

case.

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8. REMOVE FRONT BUMPER COVER CAUTION: In order to avoid damage to the wire harness, disconnect the fog light connectors. (Only for models with front fog lights)

A. REMOVE ENGINE UNDER COVER RH AND LH

(a) Remove the 2 bolts and the engine under cover RH.

(b) Remove the engine under cover LH by use of the

same procedure for the RH side.

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B. REMOVE RADIATOR GRILLE

(a) Using a clip remover, remove the 2 clips.

(b) Disengage the 6 guides.

C. REMOVE FRONT BUMPER COVER

(a) Apply protective tape, as shown in the illustration. Text in illustration *1 Protective Tape

(b) Remove the 8 screws.

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(c) Using a clip remover, remove the 4 clips.

(d) Remove the screw.

HINT: Use the same procedure for the RH side and LH

side.

(e) Using a screwdriver, turn the pin 90 degrees and

remove the pin hold clip.

HINT: Use the same procedure for the RH side and LH

side.

Text in illustration *1 Pin hold clip

(f) Disengage the 4 claws. HINT: Use the same procedure for the RH side and LH side. (g) Disconnect the each connector and remove the front bumper cover.

9. REMOVE No.3 AIR HOSE (a) Loosen the 2 hose clamps, and disconnect the

No.3 air hose.

(b) Mark and store the removed hose and clamps in a separate container.

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10. REMOVE No.2 AIR HOSE (a) Loosen the 2 hose clamps, and disconnect the

No.2 air hose.

(b) Mark and store the removed hose and clamps in a separate container.

11. DETACH UPPER RADIATOR SUPPORT SUB-ASSEMBLY

(a) Remove the 4 bolts.

(b) Pull the left side of the upper radiator support upward, and move it toward the rear of the vehicle.

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12. REMOVE INTERCOOLER ASSEMBLY (a) Unclamp the wire harness at the 2 locations.

(b) Cut off the clamp indicated in the illustration, and dispose of it.

CAUTIONS: • DO NOT cut another clamp as the wire

harness cannot be fastened. • DO NOT damage the wire harness.

(c) Unclamp the vacuum hose. NOTE: This clamp is provided on the fan shroud.

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(d) Lift the intercooler. (e) Disconnect the vacuum hose, and remove the

intercooler. NOTE: Check that the grommets and radiator support cushion are NOT left.

(f) Mark and store the removed radiator support

cushion, 2 grommets and intercooler in a separate container.

(g) Remove the clamp from the transmission case.CAUTIONS: • In order to prevent a new No.3 air hose

from being damaged due to the interference with the clamp, remove the clamp.

• The clamp will be disposed of, so it may be destroyed.

(h) Mark and store the removed clamp in a

separate container.

NOTE: This clamp is provided on the fan shroud.

13. REMOVE No.2 AIR TUBE (a) Move the radiator toward the front of the vehicle

as shown in the illustration to obtain enough work space.

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(b) Disengage the wire harness clamp. (c) Disconnect the intake air temperature sensor.

(d) Disconnect the upper vacuum hose. (e) Loosen the hose clamp, and remove the 2

bolts. (f) Remove the No.1 air hose and No.2 air tube

together. CAUTION: The intake air temperature sensor will be reused, so do NOT dispose of the removed No.2 air tube.

(g) Mark and store the 2 removed bolts in a

separate container.

14. REMOVE EGR WITH COOLER PIPE ASSEMBLY

(a) Disconnect the connector and disengage the wire harness clamp.

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(b) Disconnect the 2 connectors and remove the bolt and the wire harness clamp.

(c) Disconnect the 2 vacuum hoses. (d) Remove the bolt, and move the No.1 vacuum

switching valve away.

(e) Remove the 4 bolts and 2 nuts, and then detach the EGR with cooler pipe.

CAUTION: DO NOT disconnect the water bypass hoses.

(f) Move the EGR with cooler pipe away and fasten it somewhere with rope so that it will not impede the following operations.

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(g) Remove the gaskets from the cylinder head and electric EGR control valve respectively.

(h) Destroy the 2 removed gaskets and store them

in a separate container.

15. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY

(a) Remove the 2 bolts and electric EGR control valve.

CAUTION: DO NOT disconnect the water bypass hoses.

(b) Mark and store the 2 removed bolts in a

separate container.

(c) Move the EGR control valve away and fasten it somewhere with rope so that it will not impede the following operations.

(d) Remove the gasket from the intake air connector.

(e) Destroy the removed gasket and store it in a

separate container.

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16. REMOVE INTAKE AIR CONNECTOR AND DIESEL THROTTLE BODY ASSEMBLY

(a) Disconnect the diesel throttle body connector.

(b) Remove the nut. (c) Disengage the wire harness clamp, and

separate the wire harness.

(d) Remove the bolt, and detach the oil level gauge guide.

(e) Remove the 2 bolts and 2 nuts.

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(f) Remove the intake air connector and diesel throttle body by rotating it toward the front of the vehicle.

(g) Remove the gasket.

(h) Destroy the removed gasket and store it in a separate container.

17. REMOVE DIESEL THROTTLE BODY ASSEMBLY

(a) Using pieces of wood, clamp the intake air connector and diesel throttle body in a vise.

(b) Put matchmarks onto the diesel throttle body, intake air connector and wire harness bracket as shown in the illustration.

NOTE: In order to restore the same assembly, put matchmarks.

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(c) Remove the 4 bolts, and remove the diesel throttle body and wire harness bracket.

(d) Remove the gasket.

(e) Destroy the removed gasket and store it in a separate container.

18. REMOVE VACUUM HOSE (a) Remove the hose indicated in the illustration,

as it will be reused. CAUTION: The other vacuum hose will be disposed of together with the intake air connector, so removal of it is unnecessary.

(b) Unclamp the intake air connector from the vise.

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19. REPRODUCE MATCHMARKS (a) Put a matchmark onto the new intake air

connector at the same location as the removed one.

NOTE: In order to restore the same assembly, put matchmarks.

(b) Mark and store the removed intake air

connector in a separate container.

20. INSTALL VACUUM HOSE (a) Using pieces of wood, clamp a new intake air

connector in a vise. (b) Install the hose.

21. REINSTALL DIESEL THROTTLE BODY ASSEMBLY

(a) Clean the surface where a new gasket will be installed, and then attach the new gasket onto the intake air connector.

36

(b) Align the matchmark of the diesel throttle body with that of the intake air connector.

(c) Align the other matchmark of the diesel throttle body with that of the wire harness bracket, and then temporarily fasten the diesel throttle body, intake air connector and wire harness bracket with the bolt shown in the illustration.

(d) Attach the remaining 3 bolts, and tighten all 4 bolts. Specified torque: T = 11 N*m (112 kgf*cm, 8 ft.*lbf)

(e) Unclamp the intake air connector and the diesel

throttle body from the vise.

22. REINSTALL INTAKE AIR CONNECTOR AND DIESEL THROTTLE BODY ASSEMBLY

(a) Clean the surface where a new gasket will be installed, and then attach the new gasket onto the cylinder head sub-assembly.

(b) Attach the intake air connector and diesel throttle body to the stud bolts by rotating it

toward the rear of the vehicle as shown in the illustration.

37

(c) Fasten the intake air connector and diesel throttle body with the 2 bolts and 2 nuts. Specified torque: T = 23 N*m (235 kgf*cm, 17 ft.*lbf)

(d) Reinstall the oil level gauge guide with the bolt.Specified torque: T = 9.0 N*m (92 kgf*cm, 80 in.*lbf)

(e) Engage the wire harness clamp and install the wire harness with the nut. Specified torque: T = 8.4 N*m (86 kgf*cm, 74 in.*lbf)

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(f) Reconnect the diesel throttle body connector.

23. REINSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY

(a) Clean the surface where a new gasket will be installed, and then attach the new gasket onto the intake air connector.

(b) Apply adhesive to 2 new bolts. Adhesive: Three Bond 1324 or equivalent.

(c) Remove the rope that is fastening the EGR

control valve. (d) Reinstall the EGR control valve with the 2 bolts.

Specified torque: T = 23 N*m (235 kgf*cm, 17 ft.*lbf)

39

24. REINSTALL EGR WITH COOLER PIPE ASSEMBLY

(a) Clean the surface where a new gasket will be installed, and then orient the claws of the gasket downward, and install the gasket onto the EGR control valve.

(b) Clean the surface where another new gasket will be installed, and then orient the protruded portion of the gasket upward, and install the gasket onto the cylinder block.

NO GOOD

NO GOOD

40

(c) Remove the rope that is fastening the EGR with cooler pipe.

(d) Reinstall the EGR with cooler pipe with the 4 bolts and 2 nuts. Specified torque: T = 23 N*m (235 kgf*cm, 17 ft.*lbf)

(e) Install the bolt and the No.1 vacuum switching valve assembly. Specified torque: T = 9.0 N*m (92 kgf*cm, 80 in.*lbf)

(f) Connect the 2 vacuum hoses.

(g) Reconnect the 2 connectors and install the bolt and the wire harness clamp. Specified torque: T = 8.4 N*m (86 kgf*cm, 74 in.*lbf)

(h) Reconnect the connector and engage the wire harness clamp.

41

25. INSTALL NEW No.1 AIR HOSE (a) Install a new No.1 air hose to the diesel throttle

body with a new hose clamp. Specified torque: T = 6.0 N*m (61 kgf*cm, 53 in.*lbf)

CAUTION: After the hose clamp is tightened, the obtained torque will decrease over a certain time, and this may cause the hose to come off. In order to prevent this, the hose clamp needs to be tightened again.

(b) Wait for 3 minutes, and tighten the hose clamp

again. NOTE: The torque values applied to the 1st and 2nd steps are different, so use the correct tightening torque at each step.

Specified torque: T = 5.0 N*m (51 kgf*cm, 44 in.*lbf)

26. REMOVE INTAKE AIR TEMPERATURE SENSOR

(a) Using pieces of wood, clamp the removed No.2 air tube in a vise.

CAUTION: DO NOT clamp the connecting portions of the air tube on a vise directly so as to avoid deformation.

(b) Remove the intake air temperature sensor and

gasket. (c) Unclamp the air tube from the vise.

(d) Destroy the removed gasket, mark the

removed air tube, and store them in a separate container.

42

27. INSTALL INTAKE AIR TEMPERATURE SENSOR

(a) Using pieces of wood, clamp a new No.2 air tube in a vise.

CAUTION: DO NOT clamp the connecting portions of the air tube on a vise directly so as to avoid deformation. (b) Set a new gasket, and temporarily install the

sensor.

(c) Using an SST (O2 sensor wrench), tighten the sensor.

SST 09224-00010

Specified torque: T = 34 N*m (350 kgf*cm, 25 ft.*lbf) T’ = 29 N*m (297 kgf*cm, 21 ft.*lbf) Use a torque wrench with a fulcrum length of 180 mm (7.08 in.)

CAUTION: Use the formula shown below to calculate reading values when an extension tool is used.

(d) Unclamp the air tube from the vise.

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28. INSTALL NEW No.2 AIR TUBE (a) Temporarily install the new No.2 air tube to the

No.1 air hose with a new hose clamp. (b) Fasten the new No.2 air tube with the new bolt.

Specified torque: T = 11 N*m (112 kgf*cm, 8 ft.*lbf)

(c) Tighten the hose clamp.



(d) Wait for 3 minutes, and tighten the hose clamp

again. NOTE: The torque values applied to the 1st and 2nd steps are different, so use the correct tightening torque at each step.


44

29. REPLACE CONNECTOR HOUSING OF INTAKE AIR TEMP. SENSOR (a) Using a terminal extraction tool (supplied), disengage the internal lock of the

connector housing. (b) Pull out the internal lock from the connector housing.

(c) Using the terminal extraction tool, disengage the lock claw inside the connector, and

then pull out the black wire terminal. CAUTION: Conduct removal and insertion of the wire terminals one by one so as to avoid insertion errors.

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(d) Insert the black wire terminal into a new connector housing of the No.4 engine wire

harness (kit parts). CAUTION: Since the claw engagement position of the new connector housing is opposite to the current one, turn the wire terminal upside down when it is inserted.

(e) Similarly, remove the white wire terminal and insert it into the new connector housing.

(f) Mark and store the removed connector housing in a separate container.

(g) Check that both wire terminals have been securely connected by pulling them gently.

(h) Connect an additional wire harness (No.4 engine wire harness) to the engine wire harness for the intake air temperature sensor.

NO GOOD

46

(i) Pass a cable tie through the opening of the additional No.4 engine wire harness

connector, and position the connector in the location shown in the illustration and fasten it there.

(j) Connect the other connector of the additional No.4 engine wire harness to the intake air temperature sensor.

(k) Fasten the excess portion of the additional No.4 engine wire harness onto the engine wire harness with a cable tie as shown in the illustration.

CAUTION: In order to prevent the additional No.4 engine wire harness from being damaged, wrap the cable tie around its connector and corrugated tube.

(l) Bind the engine wire harness to the starter cable with a cable tie. CAUTION: In order to prevent the existing engine wire harness from being damaged, bind it to the starter cable so that the stud bolt will not interfere with it.

(m) Cut the excess portion of the cable ties.

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30. CUT OFF RIB OF FAN SHROUD (a) Using diagonal pliers or similar tools, cut off the rib of the fan shroud.

CAUTION: In order to prevent the hose from being damaged due to the interference with the rib, cut it off.

31. REMOVE BRACKET (for models with MMT)(a) Disengage the 2 connector clamps. NOTE: DO NOT disconnect the connectors.

(b) Remove the bolt and bracket. CAUTION: The bolt will be reused.

(c) Mark and store the removed bracket in a

separate container.

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32. INSTALL NEW BRACKET for models with MMT: (a) Align the cutout of a new bracket with the rib of

the transmission case, and then fasten the bracket with the bolt that has been removed in step (b). Specified torque: T = 12.7 N*m (130 kgf*cm, 9 ft.*lbf)

For models with M/T: (b) Align the cutout of a new bracket with the rib of

the transmission case, and then fasten the bracket with a new bolt. Specified torque: T = 12.7 N*m (130 kgf*cm, 9 ft.*lbf)

(c) Attach the wire harness clamp to the bracket.

(d) Attach the 2 connector clamps to the bracket.

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33. INSTALL NEW INTERCOOLER ASSEMBLY(a) Engage the 2 bottom bushings of the radiator,

and return the radiator into the original place.

(b) Attach protective materials (e.g. cardboard) onto both core areas of a new intercooler.

CAUTION: In order to prevent the intercooler core from being damaged during installation, protect it.

(c) By referring to the illustration, install a new No.3 air hose to the new intercooler with a

new hose clamp. (d) Tighten the new hose clamp.



(e) Wait for 3 minutes, and tighten the hose clamp again. NOTE: The torque values applied to the 1st and 2nd steps are different, so use the correct tightening torque at each step.


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(f) Attach 2 new grommets and a new radiator support cushion to the new intercooler.

(g) Set the new intercooler into place. (h) Remove the protective materials. CAUTION: Remove all the protective materials from the intercooler.

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(i) Engage the clamp.

(j) Attach a new clamp to the position 180 mm (7.08 in.) away from the clamp mentioned in step (i) above.

(k) Cut the excess portion of the clamp.

(l) Fasten the clamp onto the intercooler.

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34. REINSTALL UPPER RADIATOR SUPPORT

(a) Move the upper radiator support toward the front of the vehicle, and then return it into the original place.

(b) Fasten the upper radiator support with the 4

bolts. Specified torque: T = 5.5 N*m (56 kgf*cm, 49 in.*lbf)

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35. INSTALL NEW No.3 AIR HOSE (a) By referring to the illustration, connect the No.3 air hose with a new hose clamp. (b) Tighten the hose clamp.

CAUTION: Adjust the orientation of the hose clamp so that the hose clamp will not interfere with other components.



(c) Wait for 3 minutes, and tighten the hose clamp again. NOTE: The torque values applied to the 1st and 2nd steps are different, so use the correct tightening torque at each step.


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36. INSTALL No.2 AIR HOSE (a) By referring to the illustration, install a new No.2 air hose with 2 new hose clamps. (b) Tighten the 2 hose clamps.

CAUTION: Adjust the orientation of the hose clamp so that the hose clamp will not interfere with other components.



(c) Wait for 3 minutes, and tighten the 2 hose clamps again. NOTE: The torque values applied to the 1st and 2nd steps are different, so use the correct tightening torque at each step.


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37. REINSTALL FRONT BUMPER COVER CAUTION: Reconnect the fog light connectors.

A. INSTALL FRONT BUMPER COVER

(a) Connect the front fog light connector.

(b) Engage the 8 claws and install the front bumper

cover.

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(c) Install the pin hold clip.

NOTICE: Insert the pin hold clip with the slot aligned vertically. Do not rotate the clip after inserting it. After installation, confirm that the slot is vertical. HINT: Use the same procedure for the RH side and LH

side.

Text in illustration 1 Pin hold clip

(d) Install the 2 screws. (e) Install the 4 clips. (f) Install the 8 screws.

B. INSTALL RADIATOR GRILLE

(a) Engage the 6 guides and install the radiator grille.

(b) Install the 2 clips.

C. INSTALL ENGINE UNDER COVER RH

D. INSTALL ENGINE UNDER COVER LH.

38. REINSTALL AIR CLEANER CASE SUB-ASSEMBLY

(a) Fasten the air cleaner case with the 3 bolts. Specified torque: T = 7.8 N*m (80 kgf*cm, 69 in.*lbf)

(b) Return the air cleaner filter element.

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39. REINSTALL AIR CLEANER CAP AND HOSE SUB-ASSEMBLY (if intercooler replaced)

(a) Reinstall the air cleaner cap and hose to the air cleaner hose by tightening the clamp. Specified torque: T = 2.0 N*m (20 kgf*cm, 18 in.*lbf)

(b) Engage the 2 air cleaner case clamps. (c) Clamp the wire harness with the 4 clamps. (d) Reconnect the connector.

40. REINSTALL No.1 ENGINE COVER

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F. REPLACEMENT OF ENGINE CONTROL ECM

Component to be replaced

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1. PERFORM “LEARNING VALUES SAVE” CAUTIONS: • Replacement of the engine control ECM will cause the engine oil change reminder light to

come on earlier than the actual timing. For that reason, store the data by performing “Learning Values Save” before removing ECM.

• The “Learning Values” data can be written into other vehicles, so make sure that the data and vehicle match before write it back into the vehicle.

• In order to prevent the SSM3 from overwriting the data of other vehicles, DO NOT connect the SSM3 to other vehicles until the ongoing operation is completed. If the data stored in the SSM3 is written into a vehicle, the data will be deleted from the SSM3.

Component to be replaced

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(a) Connect the SSM3 to the DLC (Data Link Connector). (b) Turn the ignition switch to ON and turn the SSM3 on. (c) Enter the following menus: "Main Menu / Alliance Vehicle Inspection" →"Alliance

Vehicle Inspection / TREZIA Inspection" → "Main Menu / Each System Check" → "Main Menu / TCCS (engine + AT)" → "Engine Control System / Work Support" → "Work Support / Learning Values Save"

(d) By following the instructions shown on the SSM3 display, save the leaning value(s).

HINT: • This process may fail due to a problem with the wire harness or a bad connection with the DLC. Check the wire harness and DLC connection. If no problem is found with either, the ECM may be malfunctioning. • If the ECM data cannot be read for some reason, input the vehicle mileage to a new ECM using the "Vehicle Mileage Write" function.

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ONLY FOR MODELS THAT DO NOT REQUIRE REPLACEMENT OF INTERCOOLER

2. RECORD AUDIO AND AIR CONDITIONING

SETTINGS (a) When the battery cable is disconnected, the

settings for the audio, air conditioning, etc., may be reset. Therefore, make a note of the settings before disconnecting the cable from the negative (-) battery terminal.

3. TAKE MEASURES AGAINST SECURITY OF THE NAVIGATION SYSTEM

(a) In some cases, a user password is set for restart of the system after disconnection of the power supply.

(b) Obtain confirmation of the customer in advance regarding conditions of the system at the time of returning the vehicle to the customer.

4. DISCONNECT CABLE FROM NEGATIVE

BATTERY TERMINAL

CAUTION: For a vehicle with an HDD navigation system, disconnect the negative battery terminal 6 minutes after IG OFF to allow the memory processing of the navigation system to complete.

5. WEAR PROTECTIVE GLOVES

CAUTION: Wear protective gloves to prevent injuries.

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6. REMOVE NO. 1 ENGINE COVER (a) Raise the front of the No. 1 engine cover to

detach the 2 pins. Then remove the 2 No. 1 engine cover hooks from the bracket, and remove the No. 1 engine cover.

Text in Illustration *1 Pin

*2 Hook

*3 Bracket

7. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY

(a) Attach a piece of tape to the windshield to mark the position of the wiper blade.

(b) Using a screwdriver with its tip wrapped in protective tape, disengage the 3 claws and remove the front wiper arm head cap.

Text in Illustration *1 Protective Tape

Example

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(c) Remove the nut, and the front wiper main arm.

Text in Illustration *1 Front Wiper Main Arm

(d) Place cloth over the windshield, and put the removed wiper main arm onto it.

(e) Wrap tape around the front wiper sub arm, and pull it up with rope to detach the front wiper arm and blade.

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8. REMOVE FRONT NO2. FENDER TO COWL SIDE SEAL LH and RH

(a) Disengage the clip A. (b) Peel off the double – sided tape and disengage

the claw. (c) Disengage the clip A Disengage the clip B as

shown in the illustration and remove the clip A and the front No. 2 fender to cowl side seal LH.

(d) Remove front No.2 fender to cowl side seal RH by use of the same procedure as for the LH side.

9. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

(a) Place pieces of cloth to catch dripping washer fluid.

(b) Disconnect the washer hose.

(c) Remove 2 clips.

Double - sided Tape

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(d) Disengage the 5 claws and 11 guides. (e) Pull out the cowl top ventilator louver sub-assembly as shown in the illustration.

CAUTION: In order to prevent the windshield from being damaged, pull the louvers straight out, DO NOT forcibly lift them up.

NOTE: The claw positions of RHD models are different.

NO GOOD

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10. REMOVE WIPER MOTOR AND LINK ASSEMBLY

(a) Disengage the 2 clamps.

(b) Remove 2 bolts. CAUTION: When removing the bolts, DO NOT damage the windshield with the tool.

(c) Disengage the grommet and remove the

windshield wiper motor and link assembly as shown in the illustration.

Text in illustration

*1 Grommet

CAUTION: When removing the wiper motor and link, DO NOT damage the windshield.

NOTE: For RHD models, the position of the wiper motor and link assembly is different.

(d) Disconnect the wiper motor connector to completely remove the wiper motor and link.

NOTE: For RHD models, the position of the wiper motor and link assembly is different.

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11. REMOVE FRONT NO.1 VENTILATOR SEAL AND FRONT AIR SHUTTER SEAL RH

(a) Disengage the clamp and remove the front No.1 ventilator seal.

(b) By use of the same procedure for the front No.1 ventilator seal, remove the front air shutter seal RH.

12. REMOVE INNER COWL TOP TO COWL BRACE

(a) Remove the 2 bolts and the inner cowl top to cowl brace.

13. REMOVE COWL TOP INSIDE CORNER PANEL LH

(a) Separate the 2 wire harness clamps. (b) Remove the 3 bolts and cowl top inside corner

panel LH.

14. REMOVE INNER COWL TOP REINFORCEMENT

(a) Remove the 3 bolts and cowl top reinforcement inner.

.

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15. REMOVE OUTER COWL TOP PANEL (a) Remove the 6 bolts and the outer cowl top

panel.

16. REMOVE ECM (a) Release the 2 lock knobs. (b) Disconnect the 2 ECM connectors.

(c) Remove the 2 bolts and separate the brake booster vacuum pipe. (w/ Combustion Type Power Heater)

(d) Remove the 2 nuts and separate the water pipe (w/ Combustion Type Power Heater)

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(e) Remove the bolt, 2 nuts and the ECM

17. INSTALL NEW ECM (a) Install the ECM with the bolt and 2 nuts.

Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)

(b) Install the water pipe with 2 nuts.(W/ Combustion Type Power Heater)


(c) Install the brake booster vacuum pipe with the 2 bolts. (W/ Combustion Type Power Heater.


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(d) Connect the 2 ECM connectors. (e) Lock the 2 lock knobs.

18. REINSTALL OUTER COWL TOP PANEL(a) Install the outer cowl top panel with 6 bolts.

Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) (b) Engage the 2 wire harness clamps.

19. REINSTALL INNER COWL TOP REINFORCEMENT

(a) Install the cowl top reinforcement inner with 3 bolts.

.Torque: 7.0 N*m (71 kgf*cm, 61 in.*lbf)

20. REINSTALL COWL TOP INSIDE CORNER PANEL LH

(a) Install the cowl top inside corner panel LH with the 3 bolts.

Torque: 7.0 N*m (71 kgf*cm, 61 in.*lbf) (b) Install the 2 wire harness clamps

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21. REINSTALL FRONT NO1. VENTILATOR

SEAL AND FRONT AIR SHUTTER SEAL RH(a) Engage the clamp and install the front No.1

ventilator seal. (b) By use of the same procedure for the front

No/1 ventilator seal, install the front No.1 Engage the clamp and install the front air shutter seal RH.

22. REINSTALL WIPER MOTOR AND LINK ASSEMBLY

(a) Reconnect the wiper motor connector.

(b) Engage the grommet as shown in the illustration. Text in illustration

*1 Grommet

(c) Install the windshield wiper motor and link assembly with the 2 bolts.

CAUTION: When tightening the bolts, DO NOT damage the windshield with the tool.


(d) Engage the 2 clamps.

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23. REINSTALL COWL TOP VENTILATOR LOUVER SUBASSEMBLY (a) Engage the 8 guide A. (b) Engage the 5 claws and 3 guides B to install the cowl top ventilator louver sub-assembly as

shown in the illustration.

(c) Install the 2 clips.

(d) Connect the washer hose.

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24. REINSTALL FRONT NO. 2 FENDER TO COWL SIDE SEAL LH AND RH

(a) Rub off any double – sided tape remaining on the window moulding.

(b) Clean the attachment surface for the window moulding.

(c) Apply primer to the attachment surface the new front fender to cowl side seal LH.

(d) Engage the clip B and claw as shown in the illustration by the arrow to install the new front fender to cowl side seal LH.

(e) Engage the clip A. (f) Apply through pressure to the sections with

double – sided tape. (g) By use of the same procedure for the LH side,

reinstall the front No.2 fender to cowl side seal RH.

25. REINSTALL FRONT WIPER ARM AND BLADE ASSEMBLY

(a) Clean the wiper arm serrations. (b) Clean the wiper pivot serration with wire brush.


*1 Wire Brush

*a Wiper Arm Serration

*b Wiper Pivot Serration

Double - sided Tape

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(c) Engage the pivot to reinstall the front wiper sub arm.

CAUTIONS: • Apply MP grease onto the pivot before

reinstalling the front wiper sub arm. • After reinstallation, check that the pivot has

been engaged securely.

(d) Remove the protective tape.

(e) Using the tape marker attached on the windshield, reinstall the front wiper main arm into the original place. Specified torque: T = 26 N*m (265 kgf*cm, 19 ft.*lbf)

(f) Remove the tape marker and cloth.

(g) Engage the 3 claws to install the front wiper arm head cap.

26. REINSTALL NO. 1 ENGINE COVER (a) Attach the No.1 engine cover hooks to the

bracket. Then align the No. 1 engine cover grommets with the 2 pins, and press down on the No. 1 engine cover to attach the pins.


*1 Pin

*2 Grommet

*3 Hook

*4 Bracket

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G. VEHICLE RESTORATION

1. RECONNECT CABLE TO NEGATIVE BATTERY TERMINAL

2. RESTORE SYSTEM SETTINGS AFTER CONNECTING CABLE TO NEGATIVE BATTERY TERMINAL

3. PERFORM “LEARNING VALUES WRITE” CAUTIONS: • Reprogramming the engine control ECM will cause the engine oil change reminder light to

come on earlier than the actual timing. For that reason, write back the saved data into the ECM by performing the “Learning Values Write”.

• The “Learning Values” data can be written into other vehicles, so make sure that the data and vehicle match before write it back into the vehicle.

• In order to prevent the SSM3 from overwriting the data of other vehicles, DO NOT connect the SSM3 to other vehicles until the ongoing operation is completed. If the data stored in the SSM3 is written into a vehicle, the data will be deleted from the SSM3.

(a) Connect the SSM3 to the DLC. (b) Turn the ignition switch to ON and turn the SSM3 on. (c) Enter the following menus: “Main Menu / Alliance Vehicle Inspection "→" Alliance

Vehicle Inspection / TREZIA Inspection "→" Main Menu / Each System Check "→" Main Menu / TCCS (engine + AT)"→"Engine Control System / Work Support "→ "Work Support / Learning Values Write".

(d) By following the instructions shown on the SSM3 display, write the leaning values.

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HINT: • This process may fail due to a problem with the wire harness or a bad connection with the DLC3. Check the wire harness and DLC3 connection. If no problem is found with either, the ECM may be malfunctioning. • If the saved data cannot be written into a new ECM for some reason, input the vehicle mileage to the ECM using the "Vehicle Mileage Write" function.

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H. FINAL CHECKS BEFORE COMPLETION OF WORK

1. CHECK INSIDE ENGINE COMPARTMENT

(a) Check that all necessary parts are installed. (b) Check that no tools or pieces of cloth are left

inside the engine compartment.

2. CHECK AND CLEAR DTCS

3. CHECK ENGINE OIL LEVEL

4. CHECK THAT HORN WORKS (if intercooler replaced)

5. ADJUST FOG LIGHT AIM (if intercooler replaced)

Documents

TREZIA INTERCOOLER / ENGINE CONTROL ECM REPLACEMENT