Forenza 2007

Removal & Installation

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  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable and let the vehicle sit for 1 minute to deactivate the air bag.
  4.  
  5. Drain the cooling system.
  6.  
  7. Recover refrigerant from A/C system.
  8.  
  9. Tilt the steering wheel to the lowest level.
  10.  
  11. Remove the screws and the instrument cluster trim panel.
  12.  
  13. Remove the A-pillar trim panels.
  14.  
  15. Remove the screw from the rear portion of the floor console.
  16.  
  17. Remove the screws from the front portion of the floor console.
  18.  
  19. Remove the floor console.

    Click image to see an enlarged view

    Fig. Front floor console mounting screws.

  20.  
  21. Disconnect the electrical connectors.
  22.  
  23. Remove the sun sensor.
  24.  
  25. Remove the center molding.
  26.  
  27. Remove the screws and the audio system.
  28.  
  29. Disconnect the audio system electrical connectors.
  30.  
  31. Remove the instrument cluster dimmer switch assembly.
  32.  
  33. Tilt the steering wheel to the lowest level.
  34.  
  35. Remove the screws and the instrument cluster trim panel.
  36.  
  37. Disconnect the electrical connectors.
  38.  
  39. Remove the screws and the instrument cluster.
  40.  
  41. Disconnect the electrical connectors.
  42.  
  43. Remove the screws and separate the hood release cable from the hood latch release handle.
  44.  
  45. Carefully pull the instrument panel under cover until the mounting clips are released and the instrument panel under cover.
  46.  
  47. Remove the bolts from the driver-s side knee bolster.

    Click image to see an enlarged view

    Fig. Knee bolster and mounting bolts.

  48.  
  49. Remove the knee bolster.
  50.  
  51. Remove the screws and the instrument panel side covers.
  52.  
  53. Remove the nuts and the bolts securing the steering column.
  54.  
  55. Disconnect the steering column electrical connector.
  56.  
  57. Lower the steering column.
  58.  
  59. Remove bolts and screws.
  60.  
  61. Remove the connecting pieces.
  62.  
  63. Remove the bolt securing the middle of the instrument panel to the body.
  64.  
  65. Remove the instrument panel screws behind the glove box brace.
  66.  
  67. Remove the bolts securing the sides of the instrument panel to body.
  68.  
  69. Disconnect the instrument panel electrical connectors.
  70.  
  71. Remove the instrument panel.
  72.  
  73. Remove the heater/air distributor case assembly as follows:
  74.  
  75. Compress the heater hose clamps at the firewall and slide the clamps toward the engine.
  76.  
  77. Remove the 2 heater hoses from the core pipes at the firewall.
  78.  
  79. Remove the screws that secure the heater/air distributor case assembly to the firewall on the side of the heater core pipes.

    Click image to see an enlarged view

    Fig. Remove the screws that secure heater/air distributor case assembly to firewall on firewall side.

  80.  
  81. Remove the high-pressure and low-pressure pipe from the A/C expansion valve.
  82.  
  83. Remove the evaporator drain hose.
    NOTE
    Have an assistant support the heater/air distributor case from inside the vehicle.

  84.  
  85. Remove the screws that secure the heater/air distributor case assembly to the firewall on the side of the evaporator.
  86.  
  87. Disconnect the rear duct connector.
  88.  
  89. Remove the heater/air distributor case assembly from the vehicle.

    Click image to see an enlarged view

    Fig. Remove the heater/air distributor case assembly from the vehicle.

  90.  
  91. Remove the wiring harness and electrical connectors from the heater/air distributor case assembly.
  92.  
  93. Remove the screws that connect the heater core housing and the evaporator housing.
  94.  
  95. Separate the sponge from heater/air distributor case assembly.
  96.  
  97. Remove the heater core cover screws from the heater core housing.
  98.  
  99. Remove the heater core.

    Click image to see an enlarged view

    Fig. Remove the heater core from the housing.

  100.  

To install:

  1. Install the heater core into the case.
  2.  
  3. Install the screws on the heater core housing and tighten to 11 inch lbs. (1.2 Nm).
  4.  
  5. Install the sponge onto the heater/air distributor case assembly.
  6.  
  7. Install the screws that connect the heater core housing and the evaporator housing. Tighten the heater core housing-to-evaporator housing screws to 11 inch lbs. (1.2 Nm).
  8.  
  9. Connect the wiring harness and electrical connectors.
  10.  
  11. Install the heater/air distributor case assembly as follows:
  12.  
  13. Position the heater/air distributor case assembly in the vehicle.
  14.  
  15. Slowly raise the heater/air distributor case assembly into position against the firewall and hold it in
  16.  
  17. Install the high-pressure and low-pressure pipe.
  18.  
  19. Install the heater/air distributor case assembly screws at the side of evaporator through the firewall from the engine compartment side. Tighten the heater/air distributor case assembly screws to 35 inch lbs. (4 Nm).
  20.  
  21. Install the heater/air distributor case assembly screws at the side of the heater core pipes through the firewall from the engine compartment side. Tighten the heater/air distributor case assembly screw to 35 inch lbs. (4 Nm).
  22.  
  23. Install the two heater hoses.
  24.  
  25. Slide the heater hose clamps into position.
  26.  
  27. Connect the rear duct connector.
  28.  
  29. Install the instrument panel as follows:
  30.  
  31. Position the instrument panel in the vehicle.
  32.  
  33. Connect the instrument panel electrical connectors.
  34.  
  35. Install the bolts securing the sides of the instrument panel to the body and tighten to 16 ft. lbs. (22 Nm).
  36.  
  37. Install the instrument panel screws behind the glove box brace.
  38.  
  39. Install the bolts securing the middle of the instrument panel to the body and tighten to 16 ft. lbs. (22 Nm).
  40.  
  41. Install the connecting pieces with bolts and screws. Tighten the connecting pieces bolts to 16 ft. lbs. (22 Nm).
  42.  
  43. Raise the steering column and connect the steering column electrical connector.
  44.  
  45. Install the nuts and the bolts securing the steering column and tighten to 16 ft. lbs. (22 Nm).
  46.  
  47. Install the instrument panel fuse block with the screw.
  48.  
  49. Install the instrument panel side covers with the screws.
  50.  
  51. Install the knee bolster.
  52.  
  53. Install the glove box and housing.
  54.  
  55. Install the instrument cluster and trim panel.
  56.  
  57. Install the instrument cluster dimmer switch assembly.
  58.  
  59. Install the audio systems and the center molding.
  60.  
  61. Install the sun sensor.
  62.  
  63. Install the floor console.
  64.  
  65. Install the A-pillar trim panels.
  66.  
  67. Install the steering column trim cover.
  68.  
  69. Refill the cooling system with approved coolant.
  70.  
  71. Recharge the refrigerant.
  72.  
  73. Connect the negative battery cable.
  74.  
  75. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  76.  

 
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