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

WARNING: This page is about a different car, the 2004 Lexus ES 330. However, it is still accessible from the selected car via links, so may be relevant.

DISCHARGE FUEL SYSTEM PRESSURE (See FUEL SYSTEM (3MZ-FE) )
DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
DRAIN ENGINE COOLANT (See ENGINE COOLANT (3MZ-FE) )
REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS) (See REPLACEMENT )
REMOVE V-BANK COVER SUB-ASSY (See REPLACEMENT )
REMOVE AIR CLEANER CAP SUB-ASSY (See REPLACEMENT )
REMOVE EMISSION CONTROL VALVE SET (See FUEL INJECTOR ASSY (3MZ-FE) )
REMOVE INTAKE AIR SURGE TANK (See FUEL INJECTOR ASSY (3MZ-FE) )
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 setting condenser
Fig 1: Removing Engine Moving Control Rod
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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
  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 2: Disconnecting Fuel Pipe No. 1
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Fig 3: Checking Tube Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Disconnect the heater inlet water hose.
  
  Fig 4: Disconnecting Heater Inlet Water Hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the nut, then disconnect the ground cable.
4. Disconnect the 6 fuel injector connectors.
  
  Fig 5: Disconnecting Fuel Injector Connectors
  Courtesy 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 Intake Manifold
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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: Removing Water Outlet
  Courtesy 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: Disconnecting Engine Coolant Temperature Sensor Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOTE 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
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL KNOCK SENSOR
1. Install the 2 knock sensor with the 2 nuts as shown in the illustration.
  Torque: 20 N.m (199 kgf.cm, 14 ft.lbf)
2. Connect the 2 knock sensor connector.
  
  Fig 10: Installing Knock Sensor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
  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.
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.
  Torque: 15 N.m (153 kgf.cm, 11 ft.lbf)
2. Retighten the 9 water outlet mounting bolts and 2 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.
  
  Fig 11: Installing Intake Manifold
  Courtesy 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.
    
    Fig 12: Connecting Fuel Pipe No. 1
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 clam.
INSTALL ENGINE MOVING CONTROL ROD
Torque:

23 N.m (235 kgf.cm, 17 ft.lbf) for bolt A

64 N.m (653 kgf.cm, 47 ft.lbf) for bolt B

Fig 13: Installing Engine Moving Control Rod
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL INTAKE AIR SURGE TANK (See FUEL INJECTOR ASSY (3MZ-FE) )
INSTALL EMISSION CONTROL VALVE SET (See FUEL INJECTOR ASSY (3MZ-FE) )
INSTALL AIR CLEANER CAP SUB-ASSY (See REPLACEMENT )
CHECK CONNECTION OF VACUUM HOSE
CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
ADD ENGINE COOLANT (See ENGINE COOLANT (3MZ-FE) )
CHECK FOR ENGINE COOLANT LEAKS (See COOLING SYSTEM )
CHECK FOR FUEL LEAKS (See ON-VEHICLE INSPECTION )
INSTALL V-BANK COVER SUB-ASSY (See REPLACEMENT )
INSTALL FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS) (See REPLACEMENT )
SYSTEM INITIALIZATION (See PRECAUTION )