Knock Sensor - Installation

1. Install knock sensor

2. Install air pump assembly w/ bracket

3. Install intake manifold

4. Connect hoses form intake manifold

5. Connect connectors from intake manifold

6. Install fuel hose no.2

7. Install fuel hose

8. Install throttle body cover sub-assembly

9. Add engine coolant

10. Check for engine coolant leaks

11. Check for fuel leaks

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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.

1. Install the air pump assembly with the 4 bolts.

   Torque:

   16 N*m{163 kgf*cm, 12 ft.*lbf}

2. Connect the pressure sensor connector for the air injection system.

3. Connect the air switching valve connector.

4. Connect the No. 2 air hose to the air switching valve.

1. Place 2 new gaskets on the intake manifold.

2. Place the intake manifold on the cylinder heads.

3. Install and uniformly tighten the 6 bolts and 4 nuts in several steps.

   Torque:

   18 N*m{185 kgf*cm, 13 ft.*lbf}

4. Install the V-bank cover bracket to the intake manifold.

   Torque:

   7.5 N*m{76 kgf*cm, 66 in.*lbf}

5. Install the wire bracket to the intake manifold with the bolt.

   Torque:

   7.5 N*m{76 kgf*cm, 66 in.*lbf}

6. Connect the engine wire to the engine hanger and wire bracket.

7. Connect the wire protector to the intake manifold and cylinder heads with the bolt and nut.

8. Install the 2 ground cables with the 2 bolts to the RH and LH cylinder heads.

9. Connect the 2 water by-pass hoses to the throttle body.

10. Connect the 2 wire clamps to the wire clamp bracket on the RH delivery pipe.

1. Connect the vacuum hose [A] to the fuel pressure regulator.

2. Connect the PCV hose [B] to the PCV valve on the LH cylinder head.

3. Connect the EVAP hose (from the charcoal canister) [C] to the VSV for EVAP.

4. Connect the 2 vacuum hoses [D] to the VSV for the air injection system.

1. Connect the throttle control connector.

2. Connect the 2 VSV connectors for the air injection system.

3. Connect the VSV connector for the EVAP.

4. Connect the 8 injector connectors.

5. Connect the ECT sensor connector.

6. Connect the 8 ignition coil connectors.

7. Connect the 2 air fuel ratio sensor connectors.

1. Using 2 new gaskets, install the fuel main hose with the fuel pressure pulsation damper.

   Torque:

   39 N*m{400 kgf*cm, 29 ft.*lbf}

Torque:

7.5 N*m{80 kgf*cm, 66 in.*lbf}

1. Slowly fill the system with engine coolant.

   Capacity:

   12.3 liters (13.0 US qts, 10.8 lmp. qts)
   

   HINT:

   1. Use of improper coolants may damage the engine cooling system.
      
   2. Use only Toyota Super Long Life Coolant or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, and non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids).
      
   3. New Toyota vehicles are filled with Toyota Super Long Life Coolant (color is pink, premixed ethylene glycol concentration is approximately 50 % and freezing temperature is -35°C (-31°F)). When replacing the coolant, Toyota Super Long Life Coolant is recommended.
      
   4. Observe the coolant level inside the radiator by pressing the inlet and outlet radiator hoses several times by hand. If the coolant level goes down, add the coolant.
      

   NOTICE:

   Do not substitute plain water for engine coolant.

2. Install the radiator cap securely.

3. Bleed the cooling system.
   

   1. Open the heater water valve while warming up the engine.

   2. Maintain the engine speed at 2,000 to 2,500 rpm and warm up the engine.

4. Stop the engine and wait until the coolant cools down.

5. Add coolant into the reservoir until the coolant level is FULL.

1. Fill the radiator with coolant and attach a radiator cap tester.

2. Pump it to 118 kPa (1.2 kgf/cm² 17.1 psi), then check for leakage.

1. When using the intelligent tester
   

   1. Connect the intelligent tester to the DLC3.

   2. Turn the ignition switch ON and intelligent tester main switch ON.

      NOTICE:

      Do not start the engine.

   3. Select the ACTIVE TEST mode on the intelligent tester.

   4. Please refer to the intelligent tester operator's manual for further details.

2. When not using the intelligent tester
   

   1. Remove the circuit opening relay.

   2. Using a service wire, connect terminals FP and +B of the relay block.

      NOTICE:

      Pay due attention to the terminal connecting position to avoid a malfunction.

   3. Turn the ignition switch ON, and check that the fuel pump operates.

      NOTICE:

      Do not start the engine.

3. Check that there are no fuel leaks after doing maintenance anywhere on the fuel system.

4. Check that the pulsation damper screw rises up when the fuel pump operates.
   If operation is not as specified, check the following parts:

   1. Fusible link
      
   2. Fuses
      
   3. EFI main relay
      
   4. Fuel pump
      
   5. ECM
      
   6. Wiring connections
      

5. Turn the ignition switch OFF.

6. Disconnect the intelligent tester from the DLC3.