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Engine Mechanical: Removal & Installation Suzuki Forenza I

Mechanical 46 illustrations ~4853 words

Cylinder Head and Gasket Removal and Installation

Refer to CYLINDER HEAD AND GASKET REMOVAL AND INSTALLATION .

Scheme 4

Scheme 4: Cylinder Head and Gasket Cleaning
Scheme 4: Cylinder Head and Gasket Cleaning
  1. Clean the gasket surfaces of the cylinder head and the engine block.
  2. Make sure the gasket surfaces of the cylinder head and the engine block are free of nicks and heavy scratches.
  3. Clean the cylinder head bolts.
  4. Inspect the cylinder head for warpage. Refer to «Cylinder Head Inspection»(ref-257073-S03094447612007062900000) .

Scheme 5

Scheme 5: Removal
Scheme 5: Removal

Scheme 6

Scheme 6
Scheme 6

Scheme 7

Scheme 7
Scheme 7
  1. Remove the timing belt. Refer to «Timing Belt Removal and Installation»(ref-257073-S15577769162007062900000) .
  2. Disconnect the breather tube at the camshaft cover.
  3. Disconnect the engine ventilation hose at the camshaft cover.
  4. Remove the spark plug cover bolts.
  5. Remove the spark plug cover.
  6. Disconnect the ignition wires from the spark plugs.
  7. Remove the camshaft cover bolts.
  8. Remove the camshaft cover washers.
  9. Remove the camshaft cover and the camshaft cover gasket.
  10. While holding the intake camshaft firmly in place, remove the intake camshaft gear bolt.
  11. Remove the intake camshaft gear.
  12. While holding the exhaust camshaft firmly in place, remove the exhaust camshaft gear bolt.
  13. Remove the exhaust camshaft gear.
  14. Loosen the camshaft bearing cap bolts in stages of one-half to one turn.
  15. Remove the camshaft bearing cap bolts from the cylinder head.
  16. Remove the camshafts.
  17. Remove the seal ring from the camshafts.
  18. Check the camshaft and bearing seats for wear and replace them if necessary.

Installation

CAUTIONTake extreme care to prevent any scratches, nicks or damage to the camshafts.

Scheme 8

Scheme 8
Scheme 8

Scheme 9

Scheme 9
Scheme 9
  1. Lubricate the camshaft journals and the camshaft caps with engine oil.
  2. Install the intake camshaft.
  3. Install the intake camshaft caps in their original positions.
  4. Install the intake camshaft cap bolts.
  5. Install the exhaust camshaft.
  6. Install the exhaust camshaft caps in their original positions.
  7. Install the exhaust camshaft cap bolts.
  8. Tighten the camshaft cap bolts gradually and in the sequence shown for each camshaft cap. Tighten: Tighten the camshaft bearing cap bolts to 8 N.m (71 lb-in).
  9. Measure the intake camshaft end play and the exhaust camshaft end play. Refer to «Engine Specifications»(ref-257073-S42207845222007062900000) .
  10. Install the intake camshaft gear.
  11. While holding the intake camshaft firmly in place, install the intake camshaft gear bolt. Tighten: Tighten the intake camshaft gear bolt to 50 N.m (37 lb-ft) plus 60° and 15° using the angular torque gauge KM-470-B.
  12. Install the exhaust camshaft gear.
  13. While holding the exhaust camshaft firmly in place, install the exhaust camshaft gear bolt. Tighten: Tighten the exhaust camshaft gear bolt to 50 N.m (37 lb-ft) plus 60° and 15° using the angular torque gauge KM-470-B.
  14. Install the camshaft cover and the camshaft cover gasket.
  15. Install the camshaft cover washers.
  16. Install the camshaft cover bolts. Tighten: Tighten the camshaft cover bolts to 8 N.m (71 lb-in).
  17. Connect the ignition wires to the spark plugs.
  18. Install the spark plug cover.
  19. Install the spark plug cover bolts. Tighten: Tighten the spark plug cover bolts to 8 N.m (71 lb-in).
  20. Connect the breather tube to the camshaft cover.
  21. Connect the engine ventilation hose to the camshaft cover.
  22. Install the timing belt. Refer to «Timing Belt Removal and Installation»(ref-257073-S15577769162007062900000) .

Scheme 10

Scheme 10
Scheme 10

Scheme 11

Scheme 11
Scheme 11

Scheme 12

Scheme 12
Scheme 12

Scheme 13

Scheme 13
Scheme 13

Scheme 14

Scheme 14
Scheme 14

Scheme 15

Scheme 15
Scheme 15
  1. Disconnect the negative battery cable.
  2. Disconnect the Manifold Air Temperature (MAT) sensor connector.
  3. Remove the air cleaner outlet hose from the throttle body.
  4. Remove the breather tube from the camshaft cover.
  5. Remove the air cleaner housing bolts.
  6. Remove the air cleaner housing.
  7. Remove the right front wheel. Refer to «WHEEL REMOVAL AND INSTALLATION»(ref-257084-S07112425062007062900000) .
  8. Remove the right front wheel well splash shield.
  9. Remove the serpentine accessory drive belt. Refer to «SERPENTINE ACCESSORY DRIVE BELT REMOVAL AND INSTALLATION»(ref-257099-S31953438622007062900000) .
  10. Remove the crankshaft pulley bolts.
  11. Remove the crankshaft pulley.
  12. Remove the right engine mount bracket. Refer to «Engine Mount Removal and Installation»(ref-257073-S01203805602007062900000) .
  13. Remove the front timing belt cover bolts.
  14. Remove the front timing belt cover.
  15. Rotate the crankshaft at least one full turn clockwise using the crankshaft gear bolt.
  16. Align the mark on the crankshaft gear with the notch at the bottom of the rear timing belt cover.
  17. Align the camshaft gear timing marks. Use the exhaust gear mark for the exhaust gear and the intake gear mark for the intake gear, since the gears are interchangeable.
  18. Loosen the automatic tensioner bolt. To relieve the belt tension, turn the hex-key tab counterclockwise.
  19. Rotate the automatic tensioner hex-key tab clockwise until the adjust arm pointer of the timing belt automatic tensioner is aligned with the notch in the timing belt automatic tensioner bracket.
  20. Tighten the automatic tensioner bolt.
  21. Rotate the crankshaft two full turns clockwise using the crankshaft gear bolt.
  22. Check the automatic tensioner pointer.
  23. When the adjust arm pointer of the timing belt automatic tensioner is aligned with the notch on the timing belt automatic tensioner bracket, the belt is tensioned correctly. Tighten: Tighten the automatic tensioner bolt to 25 N.m (18 lb-ft).
  24. Install the front timing belt cover.
  25. Install the front timing belt cover bolts. Tighten: Tighten the front timing belt cover bolts to 6 N.m (53 lb-in).
  26. Install the crankshaft pulley.
  27. Install the crankshaft pulley bolt. Tighten: Tighten the crankshaft pulley bolt to 20 N.m (15 lb-ft).
  28. Install the right engine mount bracket. Refer to «Engine Mount Removal and Installation»(ref-257073-S01203805602007062900000) .
  29. Install the serpentine accessory drive belt. Refer to «SERPENTINE ACCESSORY DRIVE BELT REMOVAL AND INSTALLATION»(ref-257099-S31953438622007062900000) .
  30. Install the right front wheel well splash shield.
  31. Install the right front wheel. Refer to «WHEEL REMOVAL AND INSTALLATION»(ref-257084-S07112425062007062900000) .
  32. Install the air cleaner housing.
  33. Install the air cleaner housing bolts. Tighten: Tighten the air cleaner housing bolts to 10 N.m (89 lb-in).
  34. Connect the air cleaner outlet hose to the throttle body.
  35. Connect the breather tube to the camshaft cover.
  36. Connect the MAT sensor connector.
  37. Connect the negative battery cable.

Scheme 16

Scheme 16
Scheme 16

Scheme 17

Scheme 17
Scheme 17
  1. Disconnect the negative battery cable.
  2. Disconnect the Manifold Air Temperature (MAT) sensor connector.
  3. Disconnect the air cleaner outlet hose from the throttle body.
  4. Disconnect the breather tube from the camshaft cover.
  5. Remove the air cleaner housing bolts.
  6. Remove the air cleaner housing.
  7. Remove the right front wheel. Refer to «WHEEL REMOVAL AND INSTALLATION»(ref-257084-S07112425062007062900000) .
  8. Remove the right front wheel well splash shield.
  9. Remove the serpentine accessory drive belt. Refer to «SERPENTINE ACCESSORY DRIVE BELT REMOVAL AND INSTALLATION»(ref-257099-S31953438622007062900000) .
  10. Remove the crankshaft pulley bolts.
  11. Remove the crankshaft pulley.
  12. Remove the right engine mount bracket. Refer to «Engine Mount Removal and Installation»(ref-257073-S01203805602007062900000) .
  13. Remove the front timing belt cover bolts.
  14. Remove the front timing belt cover.
  15. Using the crankshaft gear bolt, rotate the crankshaft clockwise until the timing mark on the crankshaft gear is aligned with the notch at the bottom of the rear timing belt cover.
  16. Align the camshaft gears with the notch on the camshaft cover.
  17. Remove the timing belt.
  18. Loosen the automatic tensioner bolt. Turn the hex-key tab to relieve belt tension.

Scheme 18

Scheme 18
Scheme 18
  1. Align the timing mark on the crankshaft gear with the notch on the bottom of the rear timing belt cover.
  2. Align the timing marks on the camshaft gears, using the intake gear mark for the intake gear and the exhaust gear mark for the exhaust gear.
  3. Install the timing belt.
  4. Turn the hex-key tab in a clockwise direction to tension the belt. Turn until the pointer aligns with the notch.
  5. Install the automatic tensioner bolt. Tighten: Tighten the automatic tensioner bolt to 25 N.m (18 lb-ft).
  6. Rotate the crankshaft two full turns clockwise using the crankshaft pulley bolt.
  7. Recheck the automatic tensioner pointer.
  8. Install the front timing belt cover.
  9. Install the front timing belt cover bolts. Tighten: Tighten the front timing belt cover bolts to 6 N.m (53 lb-in).
  10. Install the right engine mount bracket. Refer to
  11. Install the crankshaft pulley.
  12. Install the crankshaft pulley bolts. Tighten: Tighten the crankshaft pulley bolts to 20 N.m (15 lb-ft).
  13. Install the serpentine accessory drive belt. Refer to «SERPENTINE ACCESSORY DRIVE BELT REMOVAL AND INSTALLATION»(ref-257099-S31953438622007062900000) .
  14. Install the right front wheel well splash shield.
  15. Install the right front wheel. Refer to «WHEEL REMOVAL AND INSTALLATION»(ref-257084-S07112425062007062900000) .
  16. Install the air cleaner housing.
  17. Install the air cleaner housing bolts. Tighten: Tighten the air cleaner housing bolts to 10 N.m (89 lb-in).
  18. Connect the air cleaner outlet hose to the throttle body.
  19. Connect the breather tube to the camshaft cover.
  20. Connect the MAT sensor connector.
  21. Connect the negative battery cable.

Engine Mount Removal and Installation

Tools Required

DW110-060 Engine Assembly Support Fixture

Scheme 19

Scheme 19: Removal
Scheme 19: Removal
  1. Disconnect the negative battery cable.
  2. Support the engine assembly using the engine assembly support fixture DW110-060.
  3. Disconnect the Manifold Air Temperature (MAT) sensor connector.
  4. Disconnect the air cleaner outlet hose from the throttle body.
  5. Remove the air cleaner housing bolts.
  6. Remove the air cleaner housing.
  7. Remove the right front splash shield.
  8. Remove the engine mount bracket retaining bolts.
  9. Remove the engine mount bracket.
  10. Remove the serpentine accessory drive belt. Refer to «SERPENTINE ACCESSORY DRIVE BELT REMOVAL AND INSTALLATION»(ref-257099-S31953438622007062900000) .
  11. Remove the front timing belt cover bolts.
  12. Align the crankshaft pulley timing mark with the pointer, and the camshaft gears with the timing marks on the rear cover, by turning the crankshaft gear bolt.
  13. Loosen the timing belt automatic tensioner bolt.
  14. Turn the hex-key tab to relieve belt tension.
  15. Remove the timing belt idler pulley bolt and nut.
  16. Remove the timing belt idler pulley.
  17. Remove the engine mount retaining bolts.
  18. Remove the engine mount.

Scheme 20

Scheme 20: Installation
Scheme 20: Installation
  1. Install the engine mount.
  2. Install the engine mount retaining bolts. Tighten: Tighten the engine mount retaining bolts to 45 N.m (33 lb-ft).
  3. Install the timing belt idler pulleys.
  4. Install the timing belt idler pulley bolt and nut. Tighten: Tighten the timing belt idler pulley bolt and nut to 25 N.m (18 lb-ft).
  5. Tension the timing belt by turning the timing belt automatic tensioner hex-key tab counterclockwise until the pointer is aligned to the indicator. Tighten: Tighten the timing belt automatic tensioner bolt to 25 N.m (18 lb-ft).
  6. Install the front timing belt cover.
  7. Install the front timing belt cover bolts. Tighten: Tighten the front timing belt cover bolts to 6 N.m (53 lb-in).
  8. Install the engine mount bracket and retaining bolts. Tighten: Tighten the engine mount bracket retaining bolts to 55 N.m (41 lb-ft).
  9. Remove the engine assembly support fixture DW110-060.
  10. Install the serpentine accessory drive belt. Refer to «SERPENTINE ACCESSORY DRIVE BELT REMOVAL AND INSTALLATION»(ref-257099-S31953438622007062900000) .
  11. Connect the negative battery cable.

Scheme 21

Scheme 21: Removal
Scheme 21: Removal

Scheme 22

Scheme 22
Scheme 22

Scheme 23

Scheme 23
Scheme 23

Scheme 24

Scheme 24
Scheme 24
  1. Remove the fuel pump fuse.
  2. Start the engine. After it stalls, crank the engine for 10 seconds to rid the fuel system of fuel pressure.
  3. Disconnect the negative battery cable.
  4. Disconnect the Charcoal Canister Purge (CCP) and Exhaust Gas Recirculation (EGR) solenoid from the intake manifold and loosen the bracket bolt.
  5. Drain the engine coolant. Refer to «DRAINING AND REFILLING THE COOLING SYSTEM»(ref-257072-S24557310622007062900000) .
  6. Disconnect the Manifold Air Temperature (MAT) sensor connector.
  7. Disconnect the air cleaner outlet hose from the throttle body.
  8. Disconnect the Idle Air Control (IAC) valve connector.
  9. Disconnect the Manifold Absolute Pressure (MAP) sensor connector.
  10. Disconnect the coolant hoses at the throttle body.
  11. Disconnect all of the necessary vacuum hoses, including the vacuum hose at the fuel pressure regulator and the brake booster vacuum hose at the intake manifold.
  12. Remove the generator-to-intake manifold strap bracket bolts and strap.
  13. Remove the fuel rail as an assembly. Refer to «FUEL RAIL AND INJECTORS REMOVAL AND INSTALLATION»(ref-257068-S02080634982007062900000) .
  14. Remove the generator-to-intake manifold support bracket bolts.
  15. Remove the generator-to-intake manifold support bracket.
  16. Remove the intake manifold support bracket bolt at the engine block and the intake manifold.
  17. Remove the intake manifold support bracket.
  18. Remove the intake manifold retaining bolt and nuts in the sequence shown.
  19. Remove the intake manifold.
  20. Remove the intake manifold gasket.
  21. Clean the sealing surfaces of the intake manifold and the cylinder head.

Scheme 25

Scheme 25: Installation
Scheme 25: Installation

Scheme 26

Scheme 26
Scheme 26
  1. Install the intake manifold gasket.
  2. Install the intake manifold.
  3. Install the intake manifold retaining bolt and nuts in the sequence shown. Tighten: Tighten the intake manifold retaining bolt and nuts to 22 N.m (16 lb-ft).
  4. Install the generator-to-intake manifold strap bracket and bolts. Tighten: Tighten the generator-to-intake manifold strap bracket bolts to 22 N.m (16 lb-ft).
  5. Install the intake manifold support bracket.
  6. Install the intake manifold support bracket upper bolts to the intake manifold. Tighten: Tighten the intake manifold support bracket upper bolts to the intake manifold to 25 N.m (18 lb-ft).
  7. Install the intake manifold support bracket lower bolt to the engine block. Tighten: Tighten the intake manifold support bracket lower bolt to the engine block to 25 N.m (18 lb-ft).
  8. Install the generator-to-intake manifold support bracket and bolts. Tighten: Tighten the generator-to-intake manifold support bracket bolts to 37 N.m (27 lb-ft).
  9. Install the fuel rail and injector cover as an assembly. Refer to «FUEL RAIL AND INJECTORS REMOVAL AND INSTALLATION»(ref-257068-S02080634982007062900000) .
  10. Connect all of the necessary vacuum lines that were previously disconnected.
  11. Connect the MAP sensor connector.
  12. Connect the coolant hoses to the throttle body.
  13. Connect the ETC connector.
  14. Connect the air cleaner outlet hose to the throttle body.
  15. Connect the MAT sensor connector.
  16. Connect the CCP and EGR solenoid at the intake manifold and tighten the bracket bolt. Tighten: Tighten the charcoal canister purge and exhaust gas recirculation solenoid bracket bolt to 5 N.m (44 lb-in).
  17. Install the fuel pump fuse.
  18. Connect the negative battery cable.
  19. Refill the engine cooling system. Refer to «DRAINING AND REFILLING THE COOLING SYSTEM»(ref-257072-S24557310622007062900000) .

Removal

  1. Disconnect the negative battery cable.
  2. Remove the timing belt. Refer to «Timing Belt Removal and Installation»(ref-257073-S15577769162007062900000) .
  3. Remove the spark plug cover bolts.
  4. Remove the spark plug cover.
  5. Disconnect the ignition wires from the spark plugs.
  6. Disconnect the breather tubes from the camshaft cover.
  7. Remove the camshaft cover bolts.
  8. Remove the camshaft cover washers.
  9. Remove the camshaft cover and the camshaft cover gasket.
  10. While holding the intake camshaft firmly in place, remove the intake camshaft gear bolt.
  11. Remove the intake camshaft gear.
  12. Remove the Camshaft Position (CMP) sensor.
  13. Remove the water pump.
  14. While holding the exhaust camshaft firmly in place, remove the exhaust camshaft gear bolt.
  15. Remove the exhaust camshaft gear.
CAUTIONTake extreme care to prevent any scratches, nicks or damage to the camshafts.
  1. Install the intake camshaft gear.
  2. While holding the intake camshaft firmly in place, install the intake camshaft gear bolt. Tighten: Tighten the intake camshaft gear bolt to 50 N.m (37 lb-ft) plus 60° and 15° using the angular torque gauge KM-470-B.
  3. Install the Camshaft Position (CMP) sensor.
  4. Install the water pump.
  5. Install the exhaust camshaft gear.
  6. While holding the exhaust camshaft firmly in place, install the exhaust camshaft gear bolt. Tighten: Tighten the exhaust camshaft gear bolt to 50 N.m (37 lb-ft) plus 60° and 15° using the angular torque gauge KM-470-B.
  7. Apply a 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.
  8. Install the camshaft cover and the camshaft cover gasket.
  9. Install the camshaft cover washers.
  10. Install the camshaft cover bolts. Tighten: Tighten the camshaft cover bolts to 8 N.m (71 lb-in).
  11. Connect the crankcase breather tubes to the camshaft cover.
  12. Connect the ignition wires to the spark plugs.
  13. Install the spark plug cover.
  14. Install the spark plug cover bolts. Tighten: Tighten the spark plug cover bolts to 8 N.m (71 lb-in).
  15. Install the timing belt. Refer to «Timing Belt Removal and Installation»(ref-257073-S15577769162007062900000) .
  16. Connect the negative battery cable.

Rear Timing Belt Cover Removal and Installation

Tools Required

KM-470-B Angular Torque Gauge

Scheme 27

Scheme 27: Removal
Scheme 27: Removal

Scheme 28

Scheme 28
Scheme 28
  1. Disconnect the negative battery cable.
  2. Remove the timing belt. Refer to «Timing Belt Removal and Installation»(ref-257073-S15577769162007062900000) .
  3. Remove the camshaft gears. Refer to «Camshaft Gears Removal and Installation»(ref-257073-S03421459842007062900000) .
  4. Remove the timing belt automatic tensioner bolt.
  5. Remove the timing belt automatic tensioner.
  6. Remove the timing belt idler pulley bolt and nut.
  7. Remove the timing belt idler pulleys.
  8. Remove the engine mount retaining bolts.
  9. Remove the engine mount.
  10. Remove the crankshaft gear bolt.
  11. Remove the crankshaft gear.
  12. Remove the rear timing belt cover bolts.
  13. Remove the rear timing belt cover.

Scheme 29

Scheme 29
Scheme 29
  1. Install the rear timing belt cover.
  2. Install the rear timing belt cover bolts. Tighten: Tighten the rear timing belt cover bolts to 7 N.m (62 lb-in).
  3. Install the engine mount and retaining bolts. Tighten: Tighten the engine mount retaining bolts to 45 N.m (33 lb-ft).
  4. Install the timing belt idler pulleys.
  5. Install the timing belt idler pulley bolt and nut. Tighten: Tighten the timing belt idler pulley bolt to 25 N.m (18 lb-ft). Tighten the timing belt idler pulley nut to 25 N.m (18 lb-ft).
  6. Install the crankshaft timing belt drive gear and bolt. Tighten: Tighten the crankshaft gear bolt to 145 N.m (107 lb-ft) plus 30° and plus 15° using the angular torque gauge KM-470-B.
  7. Install the timing belt automatic tensioner and bolt.
  8. Install the camshaft gears. Refer to «Camshaft Gears Removal and Installation»(ref-257073-S03421459842007062900000) .
  9. Install the timing belt and timing belt cover. Refer to «Timing Belt Removal and Installation»(ref-257073-S15577769162007062900000) .
  10. Connect the negative battery cable.

Scheme 30

Scheme 30
Scheme 30

Scheme 31

Scheme 31
Scheme 31

Scheme 32

Scheme 32
Scheme 32

Scheme 33

Scheme 33
Scheme 33

Scheme 34

Scheme 34
Scheme 34
  1. Remove the fuel pump fuse.
  2. Start the engine. After it stalls, crank the engine for 10 seconds to rid the fuel system of fuel pressure.
  3. Remove the hood. Refer to «HOOD REMOVAL AND INSTALLATION»(ref-257113-S40214582632007062900000) .
  4. Drain the engine oil.
  5. Disconnect the negative battery cable.
  6. Discharge the air conditioning (A/C) system, if equipped. Refer to «DISCHARGING, ADDING OIL, EVACUATING, AND CHARGING PROCEDURES FOR A/C SYSTEM»(ref-257102-S08954628872007062900000) .
  7. Disconnect the Manifold Air Temperature (MAT) sensor connector.
  8. Remove the air cleaner outlet hose from the throttle body and air cleaner housing.
  9. Disconnect the breather tubes from the camshaft cover.
  10. Remove the right front wheel. Refer to «WHEEL REMOVAL AND INSTALLATION»(ref-257084-S07112425062007062900000) .
  11. Remove the right front wheel well splash shield.
  12. Remove the serpentine accessory drive belt. Refer to «SERPENTINE ACCESSORY DRIVE BELT REMOVAL AND INSTALLATION»(ref-257099-S31953438622007062900000) .
  13. Drain the engine coolant. Refer to «DRAINING AND REFILLING THE COOLING SYSTEM»(ref-257072-S24557310622007062900000) .
  14. Remove the cooling system radiator and the engine cooling fans. Refer to «RADIATOR REMOVAL AND INSTALLATION»(ref-257072-S36651623422007062900000) .
  15. Disconnect the upper radiator hose from the thermostat housing.
  16. Disconnect the power steering return hose from the power steering pump.
  17. Disconnect the power steering pressure hose from the power steering pump.
  18. Disconnect the electrical connector at the Direct Ignition System (DIS) coil and the Engine Control Module (ECM) ground terminal and at the starter motor.
  19. Disconnect the Oxygen (O2) sensor connector, if equipped.
  20. Disconnect the Electric Throttle Control (ETC) connector.
  21. Disconnect the engine Coolant Temperature Sensor (CTS) connector.
  22. Disconnect the generator voltage regulator connector and power lead.
  23. Disconnect all of the necessary vacuum lines, including the brake booster vacuum hose.
  24. Disconnect the fuel return line at the fuel rail.
  25. Disconnect the fuel feed line at the fuel rail.
  26. Remove the fuel rail and injector channel cover as an assembly. Refer to «FUEL RAIL AND INJECTORS REMOVAL AND INSTALLATION»(ref-257068-S02080634982007062900000) .
  27. Disconnect the coolant hose at the throttle body.
  28. Disconnect the heater outlet hose at the coolant pipe.
  29. Disconnect the coolant bypass hose from the cylinder head.
  30. Disconnect the surge tank coolant hose from the coolant pipe.
  31. Disconnect the lower radiator hose from the coolant pipe.
  32. Disconnect the starter solenoid "S" terminal wire and power lead.
  33. Remove the A/C compressor. Refer to «COMPRESSOR REMOVAL AND INSTALLATION»(ref-257102-S10772690112007062900000) .
  34. Remove the exhaust flex pipe retaining nuts from the exhaust manifold studs.
  35. Remove the exhaust flex pipe retaining nuts from the catalytic converter or the connecting pipe.
  36. Remove the exhaust flex pipe.
  37. Remove the crankshaft pulley bolts.
  38. Remove the crankshaft pulley.
  39. Disconnect the vacuum lines at the charcoal canister purge solenoid.
  40. Disconnect the electrical connector at the Charcoal Canister Purge (CCP) and the Exhaust Gas Recirculation (EGR) solenoid.
  41. Disconnect the electrical connector at the oil pressure switch.
  42. Disconnect the Crankshaft Position Sensor (CPS) connector.
  43. Disconnect the knock sensor connector.
  44. Remove the lower reaction rod bracket bolts.
  45. Remove the lower reaction rod bracket.
  46. Remove the lower reaction rod mount bolt.
  47. Remove the lower reaction rod mount.
  48. Remove the rubber cover as a service hole.
  49. Remove the transaxle torque converter bolts through the service hole, if automatic transaxle equipped.
  50. Remove the transaxle bell housing bolts and the oil pan flange bolts.
  51. Support the transaxle with a floor jack.
  52. Install the engine lifting device.
  53. Disconnect the right engine mount bracket from the engine mount by removing the retaining bolt.
  54. Remove the right engine mount bracket from the engine block and frame mount. Refer to «Engine Mount Removal and Installation»(ref-257073-S01203805602007062900000) .
  55. Separate the engine block from the transaxle. Remove the engine.

Scheme 35

Scheme 35: Installation
Scheme 35: Installation

Scheme 36

Scheme 36
Scheme 36
  1. Install the engine into the engine compartment.
  2. Align the engine alignment pins to the transaxle.
  3. Install the transaxle bell housing bolts. Tighten: Tighten the transaxle bell housing bolts to 75 N.m (55 lb-ft).
  4. Install the oil pan flange-to-transaxle bolts. Tighten: Tighten the oil pan flange-to-transaxle bolts to 40 N.m (30 lb-ft).
  5. Install the right engine mount to the engine block mount and the frame mount.
  6. Install the right engine mount bracket retaining bolts and nuts. Tighten: Tighten the engine mount bracket retaining bolts and nuts to 55 N.m (41 lb-ft).
  7. Remove the floor jack used for support of the transmission.
  8. Remove the engine lifting device.
  9. Install the transaxle torque converter bolts, if automatic transaxle equipped. Tighten: Tighten the transaxle torque converter bolts to 60 N.m (44 lb-ft).
  10. Install the rubber cover as a service hole.
  11. Install the lower reaction rod mount.
  12. Install the lower reaction rod mount bolt. Tighten: Tighten the lower reaction rod mount bolt to 55 N.m (41 lb-ft).
  13. Install the lower reaction rod bracket.
  14. Install the lower reaction rod bracket bolts. Tighten: Tighten the lower reaction rod bracket bolt to 69 N.m (49 lb-ft).
  15. Connect the vacuum lines at the CCP solenoid.
  16. Connect the electrical connector to the CCP and the EGR solenoid.
  17. Connect the oil pressure switch connector.
  18. Install the crankshaft pulley.
  19. Install the crankshaft pulley bolts. Tighten: Tighten the crankshaft pulley bolts to 20 N.m (15 lb-ft) using a torque wrench.
  20. Connect the CPS connector.
  21. Install the exhaust flex pipe.
  22. Install the exhaust flex pipe retaining nuts to the exhaust manifold studs. Tighten: Tighten the exhaust flex pipe-to-exhaust manifold retaining nuts to 35 N.m (26 lb-ft).
  23. Install the exhaust flex pipe retaining nuts to the catalytic converter or the connecting pipe. Tighten: Tighten the exhaust flex pipe-to-catalytic converter or connecting pipe retaining nuts to 35 N.m (26 lb-ft).
  24. Connect the power steering pressure hose.
  25. Connect the power steering return hose.
  26. Install the A/C compressor, if equipped. Refer to «COMPRESSOR REMOVAL AND INSTALLATION»(ref-257102-S10772690112007062900000) .
  27. Install the serpentine accessory drive belt. Refer to «SERPENTINE ACCESSORY DRIVE BELT REMOVAL AND INSTALLATION»(ref-257099-S31953438622007062900000) .
  28. Install the right front wheel well splash shield.
  29. Install the right front wheel. Refer to «WHEEL REMOVAL AND INSTALLATION»(ref-257084-S07112425062007062900000) .
  30. Connect the fuel feed line to the fuel rail.
  31. Connect the fuel return line to fuel rail.
  32. Install the fuel rail and injector channel cover as an assembly. Refer to «FUEL RAIL AND INJECTORS REMOVAL AND INSTALLATION»(ref-257068-S02080634982007062900000) .
  33. Connect all of the necessary vacuum lines including the brake booster vacuum hose.
  34. Connect the O2 sensor connector, if equipped.
  35. Connect the starter solenoid "S" terminal wire and power lead.
  36. Connect the generator voltage regulator connector.
  37. Connect the CTS connector.
  38. Connect the engine CTS connector.
  39. Connect the ETC connector.
  40. Connect the MAP sensor connector.
  41. Connect the knock sensor, if necessary.
  42. Connect the electrical connector at the DIS ignition coil and the ECM ground terminal and at the starter motor.
  43. Install the air cleaner outlet hose between the throttle body and the air cleaner housing.
  44. Connect the breather tubes to the camshaft cover.
  45. Connect the MAT sensor connector.
  46. Install the cooling system radiator and the engine cooling fans. Refer to «RADIATOR REMOVAL AND INSTALLATION»(ref-257072-S36651623422007062900000) .
  47. Connect the lower radiator hose to the coolant pipe.
  48. Connect the upper radiator hose to the thermostat housing.
  49. Connect the heater inlet hose to the cylinder head.
  50. Connect the heater outlet hose to the coolant pipe.
  51. Connect the coolant surge tank hose to the coolant pipe.
  52. Connect the coolant hose to the throttle body.
  53. Install the fuel pump fuse.
  54. Connect the negative battery cable.
  55. Refill the engine crankcase with engine oil.
  56. Refill the engine coolant system. Refer to «DRAINING AND REFILLING THE COOLING SYSTEM»(ref-257072-S24557310622007062900000) .
  57. Bleed the power steering system. Refer to «BLEEDING THE POWER STEERING SYSTEM»(ref-257099-S13625695002007062900000) .
  58. Refill the A/C refrigerant system, if equipped. Refer to «DISCHARGING, ADDING OIL, EVACUATING, AND CHARGING PROCEDURES FOR A/C SYSTEM»(ref-257102-S08954628872007062900000) .
  59. Install the hood. Refer to «HOOD REMOVAL AND INSTALLATION»(ref-257113-S40214582632007062900000) .

Pistons and Rods Removal and Installation

Tools Required

J-8037 Universal Piston Ring Compressor

J-8087 Cylinder Bore Check Gauge

KM-427 Piston Pin Service Set

KM-470-B Angular Torque Gauge

Scheme 37

Scheme 37: Removal
Scheme 37: Removal

Scheme 38

Scheme 38
Scheme 38

Scheme 39

Scheme 39
Scheme 39

Scheme 40

Scheme 40
Scheme 40
  1. Remove the cylinder head with the intake manifold and exhaust manifold attached. Refer to «CYLINDER HEAD AND GASKET REMOVAL AND INSTALLATION»(ref-236070-S17855192712006063000000) .
  2. Remove the oil pan. Refer to «OIL PAN REMOVAL AND INSTALLATION»(ref-257075-S07273442882007062900000) .
  3. Remove the oil suction pipe bolts and support bracket bolts.
  4. Remove the oil suction pipe.
  5. Remove the crankshaft bearing bridge and the oil pan scraper bolts.
  6. Remove the crankshaft bearing bridge and the oil pan scraper.
  7. Move the piston to the bottom of the piston stroke.
  8. Mark the connecting rod cap for position.
  9. Remove the connecting rod cap bolts.
  10. Remove the connecting rod cap and the lower connecting rod bearing.
  11. Remove the upper piston connecting rod bearing.
  12. Ridge ream the cylinder wall.
  13. Remove the piston.
  14. Use a piston ring expander tool to expand the piston rings.
  15. Remove the piston rings.
  16. Remove the piston pin from the piston and connecting rod assembly using the piston pin service set KM-427.
  17. Separate the piston from the connecting rod.
CAUTIONFor ease of installation of the piston pin, the connecting rod should be heated to 280 °C. Heat the upper connecting rod only. Use commercial thermocolor material to determine the correct temperature. When the thermocolor material changes from black to green, the temperature is correct for installation.

Scheme 41

Scheme 41
Scheme 41

Scheme 42

Scheme 42
Scheme 42

Scheme 43

Scheme 43
Scheme 43

Scheme 44

Scheme 44
Scheme 44

Scheme 45

Scheme 45
Scheme 45

Scheme 46

Scheme 46
Scheme 46
  1. Align the notch on the piston and connecting rod so that the proper sides will be facing the front of the engine.
  2. Install the piston pin guide through the piston and the connecting rod.
  3. Coat the piston pin with clean oil.
  4. Install the piston pin into the opposite side of the piston.
  5. Install the piston pin into the piston and connecting rod assembly using the piston pin service set KM-427.
  6. Select a set of new piston rings.
  7. Measure the piston ring gap using a feeler gauge. Refer to «Engine Specifications»(ref-257073-S42207845222007062900000) .
  8. Increase the piston ring gap by carefully filing off excess material if the piston ring gap is below specifications.
  9. Measure the piston ring side clearance using a feeler gauge. Refer to «Engine Specifications»(ref-257073-S42207845222007062900000) .
  10. If the piston ring is too thick, try another piston ring.
  11. If no piston ring can be found that fits to specifications, the piston ring may be ground to size with emery paper placed on a sheet of glass.
  12. Install a piston oil ring, the expander, then the second piston oil ring to the bottom ring groove of the piston.
  13. Install the second compression ring to the middle ring groove of the piston.
  14. Install the top compression ring to the top ring groove of the piston.
  15. Use a piston ring expander to install the piston rings. Do not expand the piston rings beyond the expansion necessary for installation.
  16. Stagger the piston oil rings, the oil ring rail gaps, the second compression ring, and the top compression ring in relation to the notch on the top of the piston.
  17. Lubricate the cylinder wall and the piston rings with clean engine oil.
  18. Install the piston using the universal piston ring compressor J-8037 and a wood handle. Guide the lower connecting rod end to prevent damaging the crankshaft journal.
  19. Install the connecting rod cap and bearings. Refer to «Crankshaft Bearings and Connecting Rod Bearings - Gauging Plastic Inspection»(ref-257073-S11213546512007062900000) .
  20. Install the connecting rod cap bolts. Tighten: Tighten the connecting rod bearing cap bolts to 35 N.m (26 lb-ft). Using the angular torque gauge KM470-B, tighten the bolts one turn of 45° plus one turn of 15°.
  21. Install the crankshaft bearing bridge/oil pan scraper bolts. Tighten: Tighten the crankshaft bearing bridge/oil pan scraper bolts to 20 N.m (15 lb-ft) plus 45° using the angular torque gauge KM-470-B.
  22. Install the oil suction pipe.
  23. Install the oil suction pipe bolts. Tighten: Tighten the oil suction pipe bolts to 8 N.m (71 lb-in) and the oil suction pipe bracket bolt to 6 N.m (53 lb-in).
  24. Install the oil pan. Refer to «OIL PAN REMOVAL AND INSTALLATION»(ref-257075-S07273442882007062900000) .
  25. Install the cylinder head with the intake manifold and exhaust manifold attached. Refer to «CYLINDER HEAD AND GASKET REMOVAL AND INSTALLATION»(ref-236070-S17855192712006063000000) .

Scheme 47

Scheme 47: Pistons and Rods Inspection
Scheme 47: Pistons and Rods Inspection

Scheme 48

Scheme 48
Scheme 48

Scheme 49

Scheme 49
Scheme 49
  1. Inspect the connecting rod for bending or twisting. If the connecting rod is bent or twisted, replace the connecting rod.
  2. Inspect the connecting rod bearings.
  3. Inspect the connecting rod lower end for wear.
  4. Inspect the connecting rod upper end for scoring.
  5. Inspect the crankshaft rod bearing journal for wear. Refer to «Engine Specifications»(ref-257073-S42207845222007062900000) .
  6. Inspect the piston for scoring, cracks, and wear.
  7. Inspect the piston for taper using a micrometer.
  8. Inspect the piston for fit to the connecting rod.
  9. Inspect the engine block deck surface for flatness using a straight edge and a feeler gauge. Refer to «Engine Specifications»(ref-257073-S42207845222007062900000) .
  10. Inspect the bearing bore for concentricity and alignment using cylinder bore check gauge J-8087. Refer to «Engine Specifications»(ref-257073-S42207845222007062900000) . If the bearing bore is beyond specifications, replace the engine block.
  11. Inspect the engine block cylinder bore for wear, runout, ridging and taper using a bore gauge. Refer to «Engine Specifications»(ref-257073-S42207845222007062900000) .
  12. Inspect the engine block cylinder bore for glazing. Lightly hone the cylinder bore as necessary.

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