Engine Electrical Devices: Removal & Installation Suzuki Forenza I

Installation

1. Clean the gasket mating surface on the intake manifold.
2. Clean the throttle body.
3. Install the throttle body assembly with a new gasket to the intake manifold.
4. Install the throttle body retaining nuts. Tighten: Tighten the throttle body retaining nuts to 10 N.m (89 lb-in).
5. Connect the ETC connector.
6. Connect the coolant hoses to the throttle body.
7. Connect the vacuum hoses to the throttle body.
8. Install the air intake tube.
9. Connect the breather hose to the valve cover.
10. Connect the IAT sensor connector.
11. Connect the negative battery cable.
12. Fill the cooling system.

Scheme 5

1. Turn the ignition switch OFF.
2. Disconnect the Electric Throttle Control (ETC) connector from the APM.
3. Remove the bolts, three places, attaching the APM to the APM support bracket.

1. Installation should follow the removal procedure in the reverse order.
2. Tighten the APM retaining bolts to the APM support bracket. Tighten: Tighten the APM retaining bolts to 16 - 22 N.m (11.80 - 16.23 lb-ft).

Scheme 6

1. Disconnect the negative battery cable.
2. Disconnect the Intake Air Temperature (IAT) sensor connector.
3. Remove the IAT sensor by pulling it out of the air intake tube.

1. Install the IAT sensor into the air intake tube.
2. Connect the IAT connector.
3. Connect the negative battery cable.

Scheme 7

1. Disconnect the negative battery cable.
2. Disconnect the fuel rail. Refer to «FUEL RAIL AND INJECTORS REMOVAL AND INSTALLATION»(ref-257068-S02080634982007062900000) .
3. Disconnect the Manifold Absolute Pressure (MAP) sensor connector from the MAP sensor.
4. Remove the MAP sensor retaining bolt.
5. Remove the MAP sensor from the intake manifold.

1. Connect the MAP sensor connector to the MAP sensor.
2. Install the MAP sensor into the intake manifold.
3. Install the MAP sensor retaining bolt. Tighten: Tighten the MAP sensor retaining bolt to 4 N.m (35 lb-in).
4. Connect the fuel rail. Refer to «FUEL RAIL AND INJECTORS REMOVAL AND INSTALLATION»(ref-257068-S02080634982007062900000) .
5. Connect the negative battery cable.

Scheme 8

Scheme 9

1. Disconnect the negative battery cable.
2. Raise and suitably support the vehicle.
3. Disconnect electrical connector at the knock sensor.
4. Remove the bolt and the knock sensor.

1. Install the knock sensor with the bolt. Tighten: Tighten the knock sensor bolt to 20 N.m (15 lb-ft).
2. Connect the electrical connector at the knock sensor.
3. Lower the vehicle.
4. Connect the negative battery cable.

Scheme 10

Scheme 11

1. Disconnect the negative battery cable.
2. Remove the power steering pump, if equipped. Refer to «PUMP ASSEMBLY REMOVAL AND INSTALLATION»(ref-257099-S11956796732007062900000) .
3. Remove the A/C compressor. Refer to «COMPRESSOR REMOVAL AND INSTALLATION»(ref-257102-S10772690112007062900000) .
4. Remove the rear A/C compressor mounting bracket bolts and the rear A/C compressor mounting bracket.
5. Remove the accessory mounting bracket by removing the bolts.
6. Disconnect the Crankshaft Position (CKP) sensor connector.
7. Remove the CKP sensor retaining bolt.
8. Gently rotate and remove the CKP sensor from the engine block.

Scheme 12

1. Insert the CKP sensor into the engine block.
2. Install the CKP sensor retaining bolt. Tighten: Tighten the crankshaft position sensor retaining bolt to 8 N.m (71 lb-in).
3. Connect the CKP sensor connector.
4. Install the accessory mounting bracket with the bolts.
5. Install the rear A/C mounting bracket. Tighten: Tighten the rear A/C mounting bracket bolts to 35 N.m (26 lb-ft).
6. Install the A/C compressor. Refer to «COMPRESSOR REMOVAL AND INSTALLATION»(ref-257102-S10772690112007062900000) .
7. Install the power steering pump. Refer to «PUMP ASSEMBLY REMOVAL AND INSTALLATION»(ref-257099-S11956796732007062900000) .
8. Connect the negative battery cable.

Scheme 13

Scheme 14

1. Disconnect the negative battery cable.
2. Remove the engine cover.
3. Disconnect the sensor electrical connector.
4. Remove the timing belt front cover. Refer to «TIMING BELT REMOVAL AND INSTALLATION»(ref-257073-S15577769162007062900000) .
5. Remove the camshaft position sensor bolts.
6. Remove the camshaft position sensor from the top.

1. Install the camshaft position sensor and bolts. Tighten: Tighten the camshaft position bolts to 8 N.m (71 lb-in).
2. Install the timing belt front cover, the crankshaft pulley, the accessory drive belt, and the air filter. Refer to «TIMING BELT REMOVAL AND INSTALLATION»(ref-257073-S15577769162007062900000) .
3. Connect the sensor electrical connector.
4. Install the engine cover.
5. Connect the negative battery cable.

Engine Control Module Removal and Installation

Note. If ECM is replaced with new one (VIN data is still not registered) or with used one (VIN data of other vehicle has been registered previously), make sure that re-register VIN in ECM by performing VIN Registration so that VIN can be read by a scan tool.

Scheme 15

1. Disconnect the negative battery cable.
2. Remove the air intake tube and resonator.
3. Disconnect the ECM connectors from the ECM.
4. Remove the engine control module.

1. Connect the ECM connectors to the ECM.
2. Align the ECM into the mounting base.
3. Snap the ECM into its mounting base.
4. Install the ECM trim locks.
5. Install the air intake tube and resonator.
6. Connect the negative battery cable.
7. Perform a crankshaft position system variation learning procedure. Refer to «TEC (TOOTH ERROR CORRECTION) LEARN PROCEDURE»(ref-257067-S21203891432007062900000) .