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Knock Sensor (3MZ-FE): Replacement

  1. DISCHARGE FUEL SYSTEM PRESSURE (See  FUEL SYSTEM (3MZ-FE)  ) 
  2. DRAIN ENGINE COOLANT (See  REPLACEMENT  ) 
  3. REMOVE V-BANK COVER SUB-ASSY (See  REPLACEMENT  ) 
  4. REMOVE AIR CLEANER CAP SUB-ASSY (See  REPLACEMENT  ) 
  5. REMOVE EMISSION CONTROL VALVE SET (See  REPLACEMENT  ) 
  6. REMOVE INTAKE AIR SURGE TANK (See  REPLACEMENT  ) 
  7. REMOVE INTAKE MANIFOLD 
    1. Disconnect the fuel pipe No. 1.
      1. Remove the fuel pipe clamp.
      2. Pinch the tube connector and pull out the fuel pipe No. 1.
      Fig 1: Removing Fuel Pipe No. 1
      G03032663Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Check the connector for dirt, mud or other contamination. Clean if necessary.
      • Be sure to keep the tube connector, pipe and O-ring clean. They can become contaminated easily.
      • Do not use tools when disconnecting the fuel pipe.
      • Do not bend or twist the nylon tube. Protect the connector by covering it with a vinyl or plastic bag.
      • When the pipe and the connector are stuck, push and pull the connector to release it. Then pull the connector out carefully.
      Fig 2: Identifying Tube Connector And Nylon Tube
      G03032664Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Lock the hose clamp, as shown in the illustration.
    3. Disconnect the heater inlet water hose.
      Fig 3: Disconnecting Heater Inlet Water Hose
      G03032665Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the nut and disconnect the ground cable.
    5. Disconnect the 6 fuel injector connectors.
      Fig 4: Disconnecting Ground Cable And Fuel Injector Connectors
      G03032666Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Loosen and remove the intake manifold's 9 bolts and 2 nuts little by little in the numerical order shown in the illustration.
    7. Remove the intake manifold.
    NOTE: Fully removing each bolt and nut one by one may damage the intake manifold, bolts and nuts.
    Fig 5: Identifying Removal Sequence Of Intake Manifold Bolts And Nuts
    G03032667Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE ENGINE MOVING CONTROL ROD (See  REPLACEMENT  ) 
  9. REMOVE WATER OUTLET 
    1. Disconnect the radiator hose inlet.
      Fig 6: Disconnecting Radiator Hose Inlet
      G03032668Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the ECT sensor connector.
    3. Remove the clamp.
    4. Remove the 2 bolts, 2 nuts and 2 washers.
    5. Lock the hose clamp as shown in the illustration. Then remove the water outlet together with the water by-pass hose No. 1.
    6. Remove the 2 gaskets from the 2 cylinder heads.
    Fig 7: Locking Hose Clamp And Removing Water Outlet Together With Water By-Pass Hose No. 1
    G03032669Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE KNOCK SENSOR 
    1. Disconnect the 2 sensor connectors.
    2. Remove the 2 nuts and 2 sensors.
    Fig 8: Removing Knock Sensor
    G03032670Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL KNOCK SENSOR 
    1. Install the 2 sensors with the 2 nuts, as shown in the illustration.
      1. Torque: 20 N.m (199 kgf.cm, 14 ft.lbf) 
    2. Connect the 2 sensor connectors.
    Fig 9: Identifying Knock Sensor Position For Installation
    G03032671Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL WATER OUTLET 
    1. Install 2 new gaskets to the 2 cylinder heads.
    2. Install the water outlet together with the water by-pass hose No. 1 and 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 ECT sensor connector.
    6. Connect the radiator hose inlet.
  13. INSTALL ENGINE MOVING CONTROL ROD (See  REPLACEMENT  ) 
  14. INSTALL INTAKE MANIFOLD 
    1. Tighten the intake manifolds's 9 bolts and 2 nuts little by little in the numerical order shown in the illustration.
      1. Torque: 15 N.m (153 kgf.cm, 11 ft.lbf) 
      NOTE: In this case, fully tightening one of these bolts or nuts without partially tightening the other bolts or nuts in the group may damage the intake manifold, bolts and nuts.
    2. Retighten the water outlet mounting bolts and 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 10: Identifying Tightening Sequence Of Intake Manifold Bolts And Nuts
      G03032672Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Connect the fuel pipe No. 1.
      1. Push the quick connector into the pipe until it makes "click" sound.
        NOTE:
        • Check if there is any damage or contamination on the connected part.
        • After connecting, confirm that the connector and pipe are securely connected by trying to pull them apart.
      2. Install the fuel pipe clamp.
    Fig 11: Connecting Fuel Pipe No. 1
    G03032673Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL INTAKE AIR SURGE TANK (See  REPLACEMENT  ) 
  16. INSTALL EMISSION CONTROL VALVE SET (See  REPLACEMENT  ) 
  17. INSTALL AIR CLEANER CAP SUB-ASSY (See  REPLACEMENT  ) 
  18. CHECK CONNECTION OF VACUUM HOSE (See  REPLACEMENT  ) 
  19. ADD ENGINE COOLANT (See  REPLACEMENT  ) 
  20. CHECK FOR ENGINE COOLANT LEAKS (See  ON-VEHICLE INSPECTION  ) 
  21. CHECK FOR FUEL LEAKS 
  22. INSTALL V-BANK COVER SUB-ASSY (See  REPLACEMENT  ) 
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