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Knock Sensor, Intake Manifold (3MZ-FE): Replacement

  1. DISCHARGE FUEL SYSTEM PRESSURE (See  FUEL SYSTEM (3MZ-FE)  ) 
  2. DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL) 
  3. DRAIN ENGINE COOLANT (See  ENGINE COOLANT (3MZ-FE)  ) 
  4. REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS) (See  REPLACEMENT   ) 
  5. REMOVE V-BANK COVER SUB-ASSY (See  REPLACEMENT   ) 
  6. REMOVE AIR CLEANER CAP SUB-ASSY (See  REPLACEMENT   ) 
  7. REMOVE EMISSION CONTROL VALVE SET (See  REPLACEMENT  ) 
  8. REMOVE INTAKE AIR SURGE TANK (See  REPLACEMENT  ) 
  9. REMOVE ENGINE MOVING CONTROL ROD 
    1. Remove the pipe from the clamp.
    2. Remove the 4 bolts, then remove the engine moving control rod and radio setting condenser.
    Fig 1: Removing Engine Moving Control Rod
    G02939003Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE INTAKE MANIFOLD 
    1. Disconnect the fuel pipe No. 1.
      1. Remove the fuel pipe clamp.
      2. Pinch the tube connector, then pull out the fuel pipe No. 1.
      Fig 2: Removing Fuel Pipe Clamp
      G02939004Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Check around the quick connector for dirt or mud before this operation. Remove the dirt if necessary.
      • Be careful of mud because the quick connector has an O-ring which seals the pipe and quick connector that can be contaminated.
      • Do not use any tools in this operation.
      • Do not bend or twist the nylon tube. Protect the quick connector by covering it with a vinyl or plastic bag.
      • When the pipe and quick connector are stuck, push and pull the quick connector to release and pull the quick connector out carefully.
      Fig 3: Cross Sectional View Of Tube Connector
      G02939005Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 4: Disconnecting Heater Inlet Water Hose
      G02939006Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the heater inlet water hose.
    3. Remove the nut, then disconnect the ground cable.
    4. Disconnect the 6 fuel injector connectors.
      Fig 5: Disconnecting Fuel Injector Connectors
      G02939007Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. In order to remove the intake manifold, using several steps, remove the 9 bolts and 2 nuts in the sequence shown in the illustration.
    Fig 6: Removing Bolts & Nuts In Sequence
    G02939008Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE WATER OUTLET 
    1. Disconnect the bond cable No. 1 connector.
    2. Disconnect the pipe of the radiator reserve tank.
    3. Lock the hose clamp as shown in the illustration, then disconnect the radiator hose inlet.
      Fig 7: Disconnecting Radiator Hose Inlet
      G02939009Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect the engine coolant temperature sensor connector.
    5. Remove the clamp.
    6. Remove the 2 bolts, 2 nuts and 2 washers.
    7. Lock the hose clamp as shown in the illustration. Then remove the water outlet together with water by-pass hose No. 1.
    8. Remove the 2 gaskets from the 2 cylinder heads.
    Fig 8: Removing Clamps
    G02939010Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE KNOCK SENSOR 
    1. Disconnect the 2 knock sensor connectors.
    2. Remove the 2 nuts, then remove the 2 knock sensors.
    Fig 9: Removing Knock Sensor
    G02939011Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL KNOCK SENSOR 
    1. Install the 2 knock sensors with the 2 nuts as shown in the illustration.
      1. Torque: 20 N.m (204 kgf.cm, 14 ft.lbf) 
    2. Connect the 2 knock sensor connectors.
    Fig 10: Installing Method Of Knock Sensor
    G02939012Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. 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, then unlock the hose clamp.
    3. Tighten the 2 bolts, 2 nuts and 2 washers.
      1. 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 bond cable No. 3 connector.
    7. Connect the pipe of the radiator reserve tank.
    8. Connect the radiator hose inlet, then unlock the hose clamp.
  15. INSTALL INTAKE MANIFOLD 
    1. Install the intake manifold with the 9 bolts, 2 nuts and 2 washers. Using several steps, tighten the 9 bolts and 2 nuts uniformly in the sequence shown in the illustration.
      1. Torque: 15 N.m (153 kgf.cm, 11 ft.lbf) 
    2. Retighten the 9 water outlet mounting bolts and 2 nuts.
      1. Torque: 15 N.m (153 kgf.cm, 11 ft.lbf) 
    3. Install the ground cable with the nut.
      1. Torque: 8.4 N.m (86 kgf.cm, 74 in..lbf) 
    4. Connect the heater inlet water hose.
      Fig 11: Tightening Nut & Bolts In Sequence
      G02939013Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Connect the fuel pipe No. 1.
      1. Push in the quick connector to the pipe until it makes a "click" sound.
        NOTE:
        • Check the connected part for damage or foreign objects.
        • After connecting, check if the quick connector and pipe are securely connected by pulling them.
      2. Install the fuel pipe clamp.
      Fig 12: Connecting Fuel Pipe Clamp
      G02939014Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL ENGINE MOVING CONTROL ROD 
    1. Torque: 
    2. 23 N.m (235 kgf.cm, 17 ft.lbf) for bolt A 
    3. 64 N.m (653 kgf.cm, 47 ft.lbf) for bolt B 
    Fig 13: Installing Engine Moving Control Rod
    G02939015Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL INTAKE AIR SURGE TANK (See  REPLACEMENT  ) 
  18. INSTALL EMISSION CONTROL VALVE SET (See  REPLACEMENT  ) 
  19. INSTALL AIR CLEANER CAP SUB-ASSY (See  REPLACEMENT   ) 
  20. CHECK CONNECTION OF VACUUM HOSE (See  REPLACEMENT  ) 
  21. CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL) 
    1. Torque: 5.4 N.m (55 kgf.cm, 48 in..lbf) 
  22. ADD ENGINE COOLANT (See  ENGINE COOLANT (3MZ-FE)  ) 
  23. CHECK FOR ENGINE COOLANT LEAKS (See  COOLING SYSTEM (3MZ-FE)  ) 
  24. CHECK FOR FUEL LEAKS (See  ON-VEHICLE INSPECTION  ) 
  25. INSTALL V-BANK COVER SUB-ASSY (See  REPLACEMENT   ) 
  26. INSTALL FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS) (See  REPLACEMENT   ) 
  27. SYSTEM INITIALIZATION (See  CHARGING SYSTEM (3MZ-FE)  ) 
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