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Knock Sensor, Intake Manifold (2AZ-FE): Replacement

NOTE: When disconnecting the battery terminal, initialize the following system after the terminal is reconnected.
SYSTEM SPECIFICATIONS

System Refer To
Power window control system INITIALIZATION
Sliding roof system INITIALIZATION
  1. DISCHARGE FUEL SYSTEM PRESSURE (see  FUEL - FUEL SYSTEM (2AZ-FE)  ) 
  2. DRAIN ENGINE COOLANT (see  ENGINE COOLANT (2AZ-FE)  ) 
  3. DISCONNECT BATTERY NEGATIVE TERMINAL 
  4. REMOVE FRONT WIPER ARM HEAD CAP (see  WINDSHIELD WIPER MOTOR ASSY  ) 
  5. REMOVE FR WIPER ARM LH (see  WINDSHIELD WIPER MOTOR ASSY  ) 
  6. REMOVE FR WIPER ARM RH (See  WINDSHIELD WIPER MOTOR ASSY  ) 
  7. REMOVE HOOD TO COWL TOP SEAL (See  WINDSHIELD WIPER MOTOR ASSY  ) 
  8. REMOVE COWL TOP VENTILATOR LOUVER LH (See  WINDSHIELD WIPER MOTOR ASSY  ) 
  9. REMOVE WIPER LINK ASSY (See  WINDSHIELD WIPER MOTOR ASSY  ) 
  10. REMOVE COWL TOP PANEL SUB-ASSY OUTER 
    1. Remove the wire harness clamp.
    2. Remove the 7 bolts, then remove the cowl top panel outer.
      Fig 1: Removing Cowl Top Panel Sub-Assy Outer
      G03072158Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE COWL BODY MOUNTING BRACKET LOWER LH 
    1. Remove the bolt and clip, then remove cowl body mounting bracket lower.
      Fig 2: Removing Cowl Body Mounting Bracket Lower LH
      G03072159Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE ENGINE COVER SUB-ASSY NO.1 (SEE  REPLACEMENT   ) 
  13. REMOVE AIR CLEANER CAP SUB-ASSY (SEE  REPLACEMENT   ) 
  14. REMOVE THROTTLE BODY ASSY (SEE  REPLACEMENT   ) 
  15. REMOVE FUEL DELIVERY PIPE SUB-ASSY (SEE  FUEL INJECTOR ASSY (2AZ-FE)  ) 
  16. REMOVE FUEL TUBE SUB-ASSY 
    1. Remove the fuel pipe clamp No. 1.
    2. Pinch the retainer as illustrated in Fig 3, then pull the fuel tube connector out of the pipe.
      Fig 3: Removing Fuel Tube Sub-Assy
      G03072160Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:
    • Remove any dirt and foreign objects on the fuel tube connector before performing this work.
    • Do not allow any scratches or foreign objects on the parts when disconnecting, as the fuel tube connector has the O-ring that the seals the pipe.
    • Perform this work by hand. Do not use any tools.
    • Do not forcibly bend, twist or turn the nylon tube.
    • Protect the disconnected part by covering it with a vinyl bag after disconnecting the fuel tube.
    • If the fuel tube connector and pipe are stuck, push and pull to release them.
    Fig 4: Sectional View Of Fuel Tube Sub-Assy
    G03072161Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. DISCONNECT HEATER WATER INLET HOSE A 
    1. Remove the hose clamp.
      Fig 5: Removing Hose Clamp
      G03072162Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the heater water inlet hose from the heater radiator unit and cylinder head.
      Fig 6: Removing Heater Water Inlet Hose From Heater Radiator Unit
      G03072163Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. DISCONNECT HEATER WATER OUTLET HOSE A (FROM HEATER UNIT) 
    1. Remove the heater water outlet hose from the heater radiator unit and water bypass pipe.
    Fig 7: Disconnecting Heater Water Outlet Hose A (From Heater Unit)
    G03072164Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE INTAKE MANIFOLD 
    1. Disconnect the union to check valve hose from the brake booster.
      Fig 8: Disconnecting Union
      G03072165Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the camshaft timing oil control valve connector.
    3. Remove the wire harness clamp.
    4. Remove the union to check valve hose from the vacuum hose clamp.
    5. Remove the 5 bolts and 2 nuts, then remove the intake manifold.
      Fig 9: Removing Intake Manifold
      G03072166Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the gasket from the intake manifold.
      Fig 10: Removing Gasket From Intake Manifold
      G03072167Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE INTAKE MANIFOLD INSULATOR NO.1 
    1. Remove the intake manifold insulator No. 1 from the cylinder block.
      Fig 11: Removing Intake Manifold Insulator No.1
      G03072168Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE KNOCK SENSOR 
    1. Disconnect the knock sensor connector.
    2. Remove the nut, then remove the knock sensor.
      Fig 12: Removing Knock Sensor
      G03072169Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL KNOCK SENSOR 
    1. Install the knock sensor with the nut.
      1. Torque: 20 N.m (205 kgf.cm, 15 ft.lbf) 
      NOTE: Make sure that the knock sensor is in the correct direction when installing.
    2. Connect the knock sensor connector.
      Fig 13: Installing Knock Sensor
      G03072170Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSTALL INTAKE MANIFOLD INSULATOR NO.1 
    1. Install the intake manifold insulator No. 1 onto the cylinder block.
      Fig 14: Installing Intake Manifold Insulator No.1
      G03072171Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. INSTALL INTAKE MANIFOLD 
    1. Install a new gasket into the intake manifold.
      Fig 15: Installing Intake Manifold Gasket
      G03072172Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the intake manifold with the 5 bolts and 2 nuts.
      1. Torque: 30 N.m (305 kgf.cm, 22 ft.lbf) 
    3. Fit the union to check valve hose into the vacuum hose clamp.
    4. Install the wire harness clamp.
    5. Connect the camshaft timing oil control valve connector.
      Fig 16: Installing Wire Harness Clamp
      G03072173Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Connect the union to check valve hose to the brake booster.
      NOTE: Make sure that the paint mark and hose clamp are at the correct angle when installing.
      Fig 17: Connecting Union To Check Valve Hose
      G03072174Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. CONNECT HEATER WATER OUTLET HOSE A (FROM HEATER UNIT) 
    1. Install the heater water outlet hose to the water bypass pipe and heater radiator unit.
      NOTE: Make sure that the paint mark and hose clamp are at the correct angle when installing.
      Fig 18: Connecting Heater Water Outlet Hose A (From Heater Unit)
      G03072175Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. CONNECT HEATER WATER INLET HOSE A 
    1. Install the heater water inlet hose to the cylinder head and heater radiator unit.
      NOTE: Make sure that the paint mark and hose clamp are at the correct angle when installing.
      Fig 19: Connecting Heater Water Inlet Hose A
      G03072176Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the hose clamp.
      NOTE: Make sure that the paint mark and hose clamp are at the correct angle when installing.
      Fig 20: Installing Hose Clamp
      G03072177Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. INSTALL FUEL TUBE SUB-ASSY 
    1. Align the fuel tube connector with the pipe, then push the fuel tube connector until the retainer makes a "click" sound to connect the fuel tube to the pipe.
      NOTE:
      • Check that there are no scratching or foreign objects around the connected part of the fuel tube connector and pipe before performing this work.
      • After connecting the fuel tube connector, check that the fuel tube connector and pipe are securely connected by pulling them.
      Fig 21: Installing Fuel Tube Sub-Assy
      G03072178Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. INSTALL FUEL DELIVERY PIPE SUB-ASSY (SEE  FUEL INJECTOR ASSY (2AZ-FE)  ) 
  29. INSTALL THROTTLE BODY ASSY (SEE  REPLACEMENT   ) 
  30. INSTALL AIR CLEANER CAP SUB-ASSY (SEE  REPLACEMENT   ) 
  31. INSTALL COWL BODY MOUNTING BRACKET LOWER LH 
    1. Install the cowl body mounting bracket lower with the bolt and clip.
      1. Torque: 13 N.m (135 kgf.cm, 10 in.lbf) 
    Fig 22: Installing Cowl Body Mounting Bracket Lower LH
    G03072179Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. INSTALL COWL TOP PANEL SUB-ASSY OUTER 
    1. Install the cowl top panel outer with the 7 bolts.
      1. Torque: 13 N.m (135 kgf.cm, 10 in.lbf) 
    2. Install the wire harness clamp.
      Fig 23: Installing Cowl Top Panel Sub-Assy Outer
      G03072180Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. INSTALL WIPER LINK ASSY (see  WINDSHIELD WIPER MOTOR ASSY  ) 
  34. CONNECT BATTERY NEGATIVE TERMINAL 
    1. Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) 
  35. ADD ENGINE COOLANT (see  ENGINE COOLANT (2AZ-FE)  ) 
  36. CHECK FOR ENGINE COOLANT LEAKAGE (see  COOLING SYSTEM (2AZ-FE)  ) 
  37. CHECK FOR FUEL LEAKAGE (SEE  ON-VEHICLE INSPECTION  ) 
  38. INSTALL ENGINE COVER SUB-ASSY NO.1 (SEE  REPLACEMENT   ) 
  39. INSTALL COWL TOP VENTILATOR LOUVER LH 
  40. INSTALL HOOD TO COWL TOP SEAL 
  41. INSTALL FR WIPER ARM RH (See  WINDSHIELD WIPER MOTOR ASSY  ) 
  42. INSTALL FR WIPER ARM LH (See  WINDSHIELD WIPER MOTOR ASSY  ) 
  43. INSTALL FRONT WIPER ARM HEAD CAP 
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