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Knock Sensor (3MZ-FE): Replacement

  1. DISCHARGE FUEL SYSTEM PRESSURE (See  FUEL SYSTEM (3MZ-FE)  ) 
  2. DRAIN ENGINE COOLANT (See  ENGINE COOLANT (3MZ-FE)  ) 
  3. REMOVE FR WIPER ARM LH (See  WINDSHIELD WIPER MOTOR ASSY  ) 
  4. REMOVE FR WIPER ARM RH (See  WINDSHIELD WIPER MOTOR ASSY  ) 
  5. REMOVE FRONT FENDER TO COWL SIDE SEAL LH 
  6. REMOVE FRONT FENDER TO COWL SIDE SEAL RH 
  7. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSY (See  WINDSHIELD WIPER MOTOR ASSY  ) 
  8. REMOVE WINDSHIELD WIPER LINK ASSY (See  WINDSHIELD WIPER MOTOR ASSY  ) 
  9. REMOVE COWL TOP PANEL SUB-ASSY OUTER (See  REPLACEMENT  ) 
  10. REMOVE V-BANK COVER SUB-ASSY (See  REPLACEMENT  ) 
  11. REMOVE AIR CLEANER CAP SUB-ASSY (See  REPLACEMENT  ) 
  12. REMOVE EMISSION CONTROL VALVE SET (See  REPLACEMENT  ) 
  13. REMOVE INTAKE AIR SURGE TANK (See  REPLACEMENT  ) 
  14. REMOVE INTAKE MANIFOLD 
    1. Disconnect the fuel pipe No. 1.
      1. Remove the EFI fuel pipe clamp.
      2. Pinch the tube connector and then pull out the fuel pipe No. 1.
        Fig 1: Pinching Tube Connector And Pulling Out Fuel Pipe No. 1
        G03010615Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:
        • Check if there is any dirt or mud around the connector before this operation and remove the dirt as necessary.
        • Be careful of mud because the quick connector has an O-ring which seals the pipe and connector that can be contaminated.
        • Do not use any tool in this operation.
        • Do not bend or twist the nylon tube. Protect the connector by covering it with a vinyl or plastic bag.
          Fig 2: Do Not Bend Or Twist Nylon Tube
          G03010616Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        • When the pipe and the connector are stuck, push and pull the connector to release and pull the connector out carefully.
    2. Lock the hose clamp as shown in Fig 3 .
      3. Fig 3: Locking Hose Clamp
      G03010617Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the heater inlet water hose.
    4. Remove the nut and disconnect the ground cable.
    5. Disconnect the 6 fuel injector connectors.
      Fig 4: Disconnecting Fuel Injector Connectors
      G03010618Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. In order to remove the intake manifold, using several steps, remove the 9 bolts and 2 nuts in the sequence shown in Fig 5 .
      Fig 5: Removing Intake Manifold Bolts And Nuts In Sequence
      G03010619Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE ENGINE MOVING CONTROL ROD (See  REPLACEMENT  ) 
  16. REMOVE WATER OUTLET 
    1. Disconnect the radiator hose inlet.
      Fig 6: Disconnecting Radiator Hose Inlet
      G03010620Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the engine coolant temperature sensor connector.
    3. Remove the clamp.
    4. Remove the 2 bolts, 2 nuts and 2 washers.
    5. Lock the hose clamp as shown in Fig 7 and remove the water outlet together with water by-pass hose No. 1.
      6. Fig 7: Locking Hose Clamp
      G03010621Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the 2 gaskets from the 2 cylinder heads.
  17. REMOVE KNOCK SENSOR 
    1. Disconnect the 2 knock sensor connectors.
    2. Remove the 2 nuts, and then remove the 2 knock sensors.
      Fig 8: Removing Knock Sensor
      G03010622Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL KNOCK SENSOR 
    1. Install the 2 knock sensors with the 2 nuts as shown in Fig 9 .

      Torque: 20 N.m (199 kgf.cm, 14 ft.lbf) 

      Fig 9: Installing Knock Sensor
      G03010623Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the 2 knock sensor connectors.
  19. INSTALL WATER OUTLET 
    1. Install 2 new gaskets to the 2 cylinder heads.
    2. Install the water outlet together with water by-pass hose No. 1 and unlock the hose clamp.
    3. Tighten the 2 bolts, 2 nuts and 2 washers.

      Torque: 15 N.m (153 kgf.cm, 11 ft.lbf) 

    4. Install the clamp.
    5. Connect the engine coolant temperature sensor connector.
    6. Connect the radiator hose inlet.
  20. INSTALL ENGINE MOVING CONTROL ROD (See  REPLACEMENT  ) 
  21. INSTALL INTAKE MANIFOLD 
    1. Install the intake manifold with the 9 bolts, 2 nuts and 2 washers. Using several steps, tighten the bolts and nuts uniformly in the sequence shown in Fig 10 .

      Torque: 15 N.m (153 kgf.cm, 11 ft.lbf) 

      Fig 10: Installing Intake Manifold Bolts And Nuts In Sequence
      G03010624Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Retighten the water outlet mounting bolts and nuts.

      Torque: 15 N.m (153 kgf.cm, 11 ft.lbf) 

    3. Install the ground cable with the nut.

      Torque: 8.4 N.m (86 kgf.cm, 74 in.lbf) 

    4. Connect the heater inlet water hose.
    5. Connect the fuel pipe No. 1.
      1. Push in the quick connector to the pipe until it makes "click" sound.
        NOTE:
        • Check if there is any damage or foreign objects on the connected part. 
        • After connecting, check if the connector and pipe are securely connected by pulling them. 
        Fig 11: Connecting Fuel Pipe No. 1
        G03010625Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Install the EFI fuel pipe clamp.
  22. INSTALL INTAKE AIR SURGE TANK (See  REPLACEMENT  ) 
  23. INSTALL EMISSION CONTROL VALVE SET (See  REPLACEMENT  ) 
  24. INSTALL AIR CLEANER CAP SUB-ASSY (See  REPLACEMENT  ) 
  25. CHECK CONNECTION OF VACUUM HOSE (See  REPLACEMENT  ) 
  26. ADD ENGINE COOLANT (See  ENGINE COOLANT (3MZ-FE)  ) 
  27. CHECK FOR ENGINE COOLANT LEAKS (See  COOLING SYSTEM (3MZ-FE)  ) 
  28. CHECK FOR FUEL LEAKS (See  ON-VEHICLE INSPECTION  ) 
  29. INSTALL V-BANK COVER SUB-ASSY (See  REPLACEMENT  ) 
  30. INSTALL COWL TOP PANEL SUB-ASSY OUTER (See  REPLACEMENT  ) 
  31. INSTALL WINDSHIELD WIPER LINK ASSY (See  WINDSHIELD WIPER MOTOR ASSY  ) 
  32. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSY 
  33. INSTALL FRONT FENDER TO COWL SIDE SEAL RH 
  34. INSTALL FRONT FENDER TO COWL SIDE SEAL LH 
  35. INSTALL FR WIPER ARM RH (See  WINDSHIELD WIPER MOTOR ASSY  ) 
  36. INSTALL FR WIPER ARM LH (See  WINDSHIELD WIPER MOTOR ASSY  ) 
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