Forenza 2007

Cylinder Head

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Removal & Installation




CAUTION
The fuel injection system remains under pressure after the engine has been turned OFF . Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the fuel pump fuse.
  4.  
  5. Start the engine. After it stalls, crank the engine for 10 seconds to rid the fuel system of fuel pressure.
  6.  
  7. Disconnect the negative battery cable.
  8.  
  9. Disconnect the Engine Control Module (ECM) ground terminal.
  10.  
  11. Drain the engine coolant.
  12.  
  13. Remove or disconnect the following:

    Manifold Air Temperature (MAT) sensor connector
     
    Breather tube from the camshaft cover
     
    Air cleaner outlet hose from the throttle body
     
    Direct Ignition System (DIS) coil connector
     
    Oxygen (O2) sensor connector
     
    Electronic Throttle Control (ETC) connector
     
    Engine Coolant Temperature (ECT) sensor connector
     
    Coolant Temperature Sensor (CTS) connector
     
    Remove the air cleaner housing bolts and air cleaner housing
     
    Right front wheel
     
    Right front wheel well splash shield
     

  14.  
  15. Install the engine assembly support fixture DW110-060.

    Right engine mount bracket and bolts
     
    Upper radiator hose at the thermostat housing
     
    Serpentine drive belt
     
    Crankshaft pulley bolts and crankshaft pulley
     
    Front timing belt cover bolts and front timing belt cover
     
    Timing belt
     
    Breather tube at the camshaft cover
     
    Spark plug cover bolts and spark plug cover
     
    Ignition wires from the spark plugs
     
    Camshaft cover bolts, camshaft cover and camshaft cover gasket
     
    Intake camshaft gear bolt, while holding intake camshaft firmly in place
     
    Intake camshaft gear
     
    Exhaust camshaft gear bolt, while holding exhaust camshaft firmly in place
     
    Exhaust camshaft gear
     
    Timing belt automatic tensioner bolts and timing belt automatic tensioner
     
    Timing belt idler pulley bolt and nut and timing belt idler pulleys
     
    Engine mount bolts and engine mount
     
    Crankshaft gear
     
    CMP sensor
     
    Water pump
     
    Rear timing belt cover bolts and rear timing belt cover
     
    Exhaust flex pipe retaining nuts at the exhaust manifold studs
     
    All of the necessary vacuum hoses
     
    Fuel feed line at the fuel rail
     
    Alternator adjusting bracket retaining bolt and the bracket
     
    Coolant hose at the rear cylinder head and ignition coil Exhaust Gas Recirculation (EGR) bracket
     
    Surge tank coolant hose at the throttle body
     
    Fuel rail assembly
     
    Alternator-to-intake manifold support bracket bolts at cylinder head and intake manifold
     
    Alternator support bracket
     
    Intake manifold-to-generator strap bracket bolt and loosen bolt on alternator
     
    Move the strap clear of the intake manifold.
     
    Charcoal Canister Purge (CCP) and EGR solenoid bracket bolt and move bracket clear
     
    Throttle cable at throttle body and intake manifold
     
    Loosen all cylinder head bolts gradually and in reverse order of tightening
     
    Camshafts
     
    Cylinder head bolts
     
    Cylinder head with intake manifold and exhaust manifold attached
     
    Cylinder head gasket
     

  16.  
  17. Clean the cylinder block and cylinder head mating surfaces of any old gasket material, oil or dust and clean any engine coolant from the cylinders.
  18.  

To install:

  1. Install or connect the following:

    New cylinder head gasket
     
    Cylinder head with intake manifold and exhaust manifold attached
     
    Cylinder head bolts. Tighten the cylinder head bolts gradually and in the sequence shown. Tighten the cylinder head bolts to 18 ft. lbs. (25 Nm) and turn the bolts another 3 turns of 90 degrees using the angular torque gauge KM-470-B.

    Click image to see an enlarged view

    Fig. Cylinder head bolt tightening sequence

     
    Camshafts
     
    Throttle cable at throttle body and intake manifold
     
    Alternator-to-intake manifold support bracket
     
    Alternator-to-intake manifold support bracket bolts and tighten to 27 ft. lbs. (37 Nm)
     
    Intake manifold support bracket bolt to alternator and tighten to 16 ft. lbs. (22 Nm)
     
    Surge tank coolant hose at throttle body
     
    Coolant hose to rear cylinder head and ignition coil EGR bracket
     
    Fuel feed line at the fuel rail