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
     
    Fuel return line at the fuel rail
     
    All necessary vacuum hoses
     
    Fuel rail assembly
     
    Exhaust flex pipe retaining nuts at the exhaust manifold studs and tighten to 26 ft. lbs. (35 Nm)
     
    Rear timing belt cover. Tighten the rear timing belt cover bolts to 62 inch lbs. (7 Nm).
     
    Engine mount and retaining bolts. Tighten the engine mount retaining bolts to 33 ft. lbs. (45 Nm).
     
    CMP sensor
     
    Crankshaft gear
     
    Water pump
     
    Timing belt automatic tensioner. Tighten the timing belt automatic tensioner bolts to 18 ft. lbs. (25 Nm).
     
    Timing belt idler pulleys, bolt and nut. Tighten the timing belt idler pulley bolt to 18 ft. lbs. (25 Nm).
     
    Camshaft gears with the timing marks at the front
     
    Guide pin of the intake camshaft into -IN- bore
     
    Guide pin of the exhaust camshaft into -EX- bore
     
    Camshaft gears by counter holding on the hex of the camshaft with an open-ended wrench
     
    Intake camshaft gear with a new bolt to the camshaft. Tighten the intake camshaft gear bolt to 37 ft. lbs. (50 Nm) turn the bolt another 60 degrees and 15 degrees using the angular torque gauge.
     
    Exhaust camshaft gear bolt while holding the exhaust camshaft firmly in place. Tighten the exhaust camshaft gear bolt to 37 ft. lbs. (50 Nm) turn the bolt another 60 degrees and 15 degrees using the angular torque gauge.
     
    Small amount of gasket sealant to the corners of the front camshaft caps and to the top of the rear camshaft cover-to-cylinder head seal
     
    Camshaft cover, gasket and washers
     
    Camshaft cover bolts and tighten to 71 inch lbs. (8 Nm)
     
    Ignition wires to the spark plugs
     
    Spark plug cover and tighten the spark plug cover bolts to 71 inch lbs. (8 Nm)
     
    Breather tube to the camshaft cover
     
    Timing belt
     
    Front timing belt cover
     
    Crankshaft pulley. Tighten the crankshaft pulley bolts to 106 inch lbs. (12 Nm).
     
    Right engine mount bracket. Tighten the engine mount bracket retaining bolts to 41 ft. lbs. (55 Nm).
     

  2.  
  3. Remove the engine assembly lift support DW110-060.

    Serpentine drive belt
     
    Upper radiator hose to thermostat housing
     
    Right front wheel well splash shield
     
    Right front wheel
     
    Air cleaner housing
     
    Air cleaner outlet hose to the throttle body
     
    Breather tube to the camshaft cover
     
    MAT sensor connector
     
    CTS connector
     
    Engine CTS connector
     
    ETC connector
     
    CCP and EGR solenoid bracket bolt and tighten to 44 inch lbs. (5 Nm)
     
    DIS coil connector
     
    O2 sensor connector
     
    ECM ground terminal
     
    Fuel pump fuse
     

  4.  
  5. Refill the engine cooling system.
  6.  
  7. Connect the negative battery cable.
  8.  
  9. Start the engine and check for leaks.
  10.  

 
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