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Knock Sensor: Replacement

WARNING: This page is about a different car, the 2004 Lexus LS 430. However, it is still accessible from the selected car via links, so may be relevant.
  1. DRAIN ENGINE COOLANT (See  ENGINE COOLANT  ) 
  2. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT (See  PRECAUTION  ) 
  3. REMOVE V-BANK COVER 
  4. REMOVE INTAKE AIR CONNECTOR PIPE 
  5. REMOVE THROTTLE BODY ASSY (See  REPLACEMENT  ) 
  6. REMOVE INTAKE MANIFOLD ASSY 
    1. Disconnect the fuel pipe sub-assy No. 2 from the fuel main tube (See PRECAUTION ).
    2. Disconnect the VSV connector for EVAP.
    3. Disconnect the EVAP hose from the VSV for EVAP.
    4. Remove the bolt, disconnect the VSV for EVAP from the upper intake manifold.
    5. Remove the bolt and V-bank cover bracket No. 2.
    6. Remove the bolt and V-bank cover bracket No. 3.
      Fig 1: Removing Intake Manifold Assy Components (1 Of 3)
      G01049394Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Disconnect the VSV connector for IAC Valve.
    8. Remove the bolt and V-bank cover bracket No. 1.
    9. Remove the bolt and V-bank cover bracket No. 4.
      Fig 2: Removing Intake Manifold Assy Components (2 Of 3)
      G01049395Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Remove the 4 bolts, and disconnect the engine wire protector (LH side) from upper intake manifold and camshaft bearing cap.
    11. Disconnect the 2 wire clamps on the engine wire (RH side) from the brackets on the RH delivery pipe.
    12. Remove the 2 bolts, and disconnect the engine wire protector (rear side) from the rear water by-pass joint and RH cylinder head.
      Fig 3: Removing Intake Manifold Assy Components (3 Of 3)
      G01049396Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    13. Disconnect the 8 injector connectors.
    14. Remove the 6 bolts, 4 nuts, the upper and lower intake manifolds assembly and 2 gaskets.
      Fig 4: Removing Upper And Lower Intake Manifolds Assembly Bolts And Nuts
      G01049397Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE KNOCK SENSOR 
    1. Disconnect the 2 knock sensor connectors.
    2. Remove the 2 nuts and 2 knock sensors.
      Fig 5: Removing Knock Sensor
      G01049398Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL KNOCK SENSOR 
    1. Install the 2 knock sensors with the 2 nuts, as shown in the illustration.

      Torque: 20 N.m (204 kgf.cm, 15 ft.lbf) 

    2. Connect the 2 knock sensor connectors.
      Fig 6: Installing Knock Sensor
      G01049399Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL INTAKE MANIFOLD ASSY 
    1. Place 2 new gaskets on the cylinder heads with the white mark facing outward.
      NOTE: Be careful of the installation direction.
      Fig 7: Identifying White Mark On Cylinder Heads
      G01049400Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the upper and lower intake manifolds assembly with the 6 bolts and 4 nuts.

      Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) 

    3. Connect the 8 injector connectors.
      Fig 8: Installing Upper And Lower Intake Manifolds Assembly Nuts And Bolts
      G01049401Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the engine wire protector (rear side0 with the 2 bolts.
    5. Install the engine wire protector (LH side) with the 4 bolts.
    6. Install the 2 wire clamps on the engine wire (RH side) to the brackets on the RH delivery pipe.
      Fig 9: Installing Intake Manifold Assy Components (1 Of 3)
      G01049402Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Install the V-bank cover bracket No. 4 with bolt.

      Torque: 7.5 N.m (76.5 kgf.cm, 66 in.lbf) 

    8. Install the V-bank cover bracket No. 1 with bolt.

      Torque: 7.5 N.m (76.5 kgf.cm, 66 in.lbf) 

    9. Connect the VSV connector for IAC Valve.
      Fig 10: Installing Intake Manifold Assy Components (2 Of 3)
      G01049403Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Install the V-bank cover bracket No. 3 with bolt.

      Torque: 7.5 N.m (76.5 kgf.cm, 66 in.lbf) 

    11. Install the V-bank cover bracket No. 2 with bolt.

      Torque: 7.5 N.m (76.5 kgf.cm, 66 in.lbf) 

    12. Connect the VSV for EVAP to the intake manifold with the bolt.

      Torque: 7.5 N.m (76.5 kgf.cm, 66 in.lbf) 

    13. Connect the EVAP hose to the VSV for EVAP.
    14. Connect the VSV connector for EVAP.
      Fig 11: Installing Intake Manifold Assy Components (3 Of 3)
      G01049404Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    15. Connect the fuel pipe sub-assy No. 2 to the fuel main tube (See PRECAUTION ).
  10. INSTALL THROTTLE BODY ASSY (See  REPLACEMENT  ) 
  11. INSTALL INTAKE AIR CONNECTOR PIPE 
  12. INSPECT FUEL PUMP OPERATION AND CHECK FOR FUEL LEAKS (See  ON-VEHICLE INSPECTION  ) 
  13. INSTALL V-BANK COVER 

    Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf) 

  14. REFILL ENGINE COOLANT (See  ENGINE COOLANT  ) 
  15. CHECK FOR ENGINE COOLANT LEAKS (See  INSPECTION  ) 
  16. POWER WINDOW CONTROL SYSTEM INITIALIZE (See  INITIALIZATION  ) 
  17. FRONT POWER SEAT CONTROL SYSTEM INITIALIZE (See  INITIALIZATION  ) 
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