Forenza 2007

Engine

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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. Properly relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the fuel pump fuse.
  8.  
  9. Start the engine. After it stalls, crank the engine for 10 seconds to rid the fuel system of fuel pressure.
  10.  
  11. Drain the engine oil.
  12.  
  13. Discharge the Air Conditioning (A/C) system, if equipped.
  14.  
  15. Drain the engine coolant.
  16.  
  17. Remove or disconnect the following:

    Hood
     
    Manifold Air Temperature (MAT) sensor connector
     
    Air cleaner outlet hose from throttle body and air cleaner housing
     
    Breather tubes from the camshaft cover
     
    Right front wheel.
     
    Right front wheel well splash shield
     
    Serpentine accessory drive belt.
     
    Cooling system radiator and the engine cooling fans
     
    Upper radiator hose from the thermostat housing
     
    Power steering return hose from the power steering pump
     
    Power steering pressure hose from the power steering pump
     
    Electrical connector at the direct ignition system (DIS) coil and the electronic control module (ECM) ground terminal and at the starter motor
     
    Oxygen (O2) sensor connector, if equipped
     
    Idle Air Control (IAC) valve connector
     
    Throttle Position Sensor (TPS) connector
     
    Engine Coolant Temperature Sensor (CTS) connector
     
    Alternator voltage regulator connector and power lead
     
    All of the necessary vacuum lines, including the brake booster vacuum hose
     
    Fuel return line at the fuel rail
     
    Fuel feed line at the fuel rail
     
    Fuel rail and injector channel cover as an assembly
     
    Throttle cable from the throttle body and the intake manifold bracket
     
    Coolant hose at the throttle body
     
    Heater outlet hose at the coolant pipe
     
    Coolant bypass hose from the cylinder head
     
    Surge tank coolant hose from the coolant pipe
     
    Lower radiator hose from the coolant pipe
     
    Starter solenoid terminal wire and power lead
     
    A/C compressor
     
    Exhaust flex pipe retaining nuts from the exhaust manifold studs
     
    Exhaust flex pipe retaining nuts from the catalytic converter or the connecting pipe
     
    Exhaust flex pipe
     
    Crankshaft pulley bolts and crankshaft pulley
     
    Vacuum lines at the charcoal canister purge solenoid
     
    Electrical connector at the charcoal canister purge (CCP) and the exhaust gas recirculation (EGR) solenoid
     
    Electrical connector at the oil pressure switch
     
    Crankshaft Position Sensor (CPS) connector
     
    Knock sensor connector
     
    Lower reaction rod bracket bolts
     
    Lower reaction rod bracket
     
    Lower reaction rod mount bolt
     
    Lower reaction rod mount
     
    Rubber cover from service hole
     
    Transaxle torque converter bolts through the service hole (A/T)
     
    Transaxle bell housing bolts and the oil pan flange bolts
     

  18.  
  19. Support the transaxle with a floor jack.
  20.  
  21. Install the engine lifting device.
  22.  
  23. Disconnect the right engine mount bracket from the engine mount by removing the retaining bolt.
  24.  
  25. Remove the right engine mount bracket from the engine block and frame mount.
  26.  
  27. Separate the engine block from the transaxle. Remove the engine.
  28.  

To install:

  1. Install the engine into the engine compartment
  2.  
  3. Align the engine alignment pins to the transaxle.
  4.  
  5. Install the transaxle bell housing bolts and tighten to 55 ft. lbs. (75 Nm).
  6.  
  7. Install the oil pan flange-to-transaxle bolts and tighten to 30 ft. lbs. (40 Nm).
  8.  
  9. Install or connect the following:

    Right engine mount to engine block mount and frame mount
     
    Right engine mount bracket retaining bolts and nuts. Tighten the engine mount bracket retaining bolts and nuts to 41 ft. lbs. (55 Nm).
     

  10.  
  11. Remove the floor jack used for support of the transmission.
  12.  
  13. Remove the engine lifting device.
  14.  
  15. Install or connect the following:

    Transaxle torque converter bolts (A/T) and tighten to 44 ft. lbs. (60 Nm)
     
    Rubber service hole cover
     
    Lower reaction rod mount
     
    Lower reaction rod mount bolt and tighten to 41 ft. lbs. (55 Nm)
     
    Lower reaction rod bracket
     
    Lower reaction rod bracket bolts and tighten to 49 ft. lbs. (69 Nm)
     
    Vacuum lines at the CCP solenoid
     
    Electrical connector to the CCP and the EGR solenoid
     
    Oil pressure switch connector
     
    Crankshaft pulley and crankshaft pulley bolts. Tighten the crankshaft pulley bolts to 15 ft. lbs. (20 Nm) using a torque wrench.
     
    CPS connector
     
    Exhaust flex pipe
     
    Exhaust flex pipe retaining nuts to the exhaust manifold studs and tighten to 26 ft. lbs. (35 Nm)
     
    Exhaust flex pipe retaining nuts to the catalytic converter or the connecting pipe and tighten to 26 ft. lbs. (35 Nm)
     
    Power steering pressure hose
     
    Power steering return hose
     
    A/C compressor, if equipped
     
    Serpentine drive belt
     
    Right front wheel well splash shield
     
    Right front wheel
     
    Fuel feed line to the fuel rail
     
    Fuel return line to fuel rail
     
    Fuel rail and injector channel cover as an assembly
     
    All necessary vacuum lines including brake booster vacuum hose
     
    O2 sensor connector, if equipped
     
    Starter solenoid terminal wire and power lead
     
    Alternator voltage regulator connector
     
    Engine CTS connector
     
    TPS connector
     
    IAC valve connector
     
    MAP sensor connector
     
    Knock sensor, if necessary
     
    Electrical connector at the DIS ignition coil and the ECM ground terminal and at the starter motor
     
    Air cleaner outlet hose between the throttle body and air cleaner housing
     
    Breather tubes to the camshaft cover
     
    MAT sensor connector
     
    Cooling system radiator and engine cooling fans
     
    Lower radiator hose to the coolant pipe
     
    Upper radiator hose to the thermostat housing
     
    Heater inlet hose to the cylinder head
     
    Heater outlet hose to coolant pipe
     
    Coolant surge tank hose to coolant pipe
     
    Coolant hose to throttle body
     
    Throttle cable to throttle body and intake manifold bracket
     

  16.  
  17. Install the fuel pump fuse.
  18.  
  19. Connect the negative battery cable.
  20.  
  21. Refill the engine crankcase with engine oil.
  22.  
  23. Refill the engine coolant system.
  24.  
  25. Bleed the power steering system.
  26.  
  27. Recharge the A/C refrigerant system, if equipped.
  28.  
  29. Install the hood.
  30.  
  31. Run the engine and verify that there are no fuel, coolant, transaxle or exhaust leaks.
  32.  

 
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