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Knock Control Sensor (1GR-FE (2WD): Replacement

  1. DISCHARGE FUEL SYSTEM PRESSURE  (See PRECAUTION )
  2. REMOVE BATTERY 
  3. DRAIN ENGINE COOLANT  (See REPLACEMENT )
  4. DRAIN ENGINE OIL  (See REPLACEMENT )
  5. REMOVE ENGINE ASSY  (See REPLACEMENT )
  6. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSY  (See REPLACEMENT )
  7. REMOVE COOL AIR INLET NO.1 
    1. Remove the 2 bolts, then remove the cool air inlet.
  8. REMOVE EXHAUST FRONT PIPE ASSY NO.2  (See Removal & Installation and Disassembly & Reassembly )
  9. REMOVE EXHAUST PIPE ASSY FRONT  (See Removal & Installation and Disassembly & Reassembly )
  10. REMOVE MANIFOLD STAY 
    1. Remove the 3 bolts, then remove the exhaust manifold stay.
  11. REMOVE EXHAUST MANIFOLD SUB-ASSY RH 
    1. Disconnect the air fuel ratio sensor connector.
    2. Remove the 6 nuts, then remove the exhaust manifold and gasket.
  12. REMOVE INTAKE MANIFOLD  (See REPLACEMENT )
  13. REMOVE WATER BYPASS JOINT RR  (See REPLACEMENT )
  14. REMOVE CHAIN VIBRATION DAMPER NO.1 
    1. Remove the 2 bolts, then remove the chain vibration damper No. 1.
  15. REMOVE CAMSHAFT TIMING GEARS AND NO.2 CHAIN (RH BANK)  (See REPLACEMENT )
  16. REMOVE CHAIN TENSIONER ASSY NO.2  (See REPLACEMENT - 1GR-FE and REPLACEMENT - 1GR-FE (2WD) )
  17. REMOVE CAMSHAFTS  (See REPLACEMENT - 1GR-FE and REPLACEMENT - 1GR-FE (2WD) )
  18. REMOVE CAMSHAFT BEARING NO.2  (See REPLACEMENT )
  19. REMOVE CYLINDER HEAD SUB-ASSY  (See REPLACEMENT )
  20. DISCONNECT HEATER WATER INLET HOSE 
    Fig 1: Disconnecting Heater Water Inlet Hose
    G03081614Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE WATER OUTLET PIPE NO.1 
    1. Remove the 4 wire harness clamps.
    2. Remove the 3 bolts and water outlet pipe.
      Fig 2: Removing 4 Wire Harness Clamps
      G03081615Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE KNOCK CONTROL SENSOR 
    1. Disconnect the 2 knock sensor connectors.
    2. Remove the 2 bolts and 2 knock sensors.
      Fig 3: Disconnecting Knock Sensor Connectors
      G03081616Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSTALL KNOCK CONTROL SENSOR 
    1. Install the 2 knock sensors with the 2 bolts as shown in the illustration.

      Torque: 20 N.m (204 kgf.cm, 15 ft.lbf) 

    2. Connect the 2 knock sensor connectors.
      Fig 4: Connecting Knock Sensor Connectors
      G03081617Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. INSTALL WATER OUTLET PIPE NO.1 
    1. Install the water outlet pipe with the 3 bolts.

      Torque: 9.0 N.m (92 kgf.cm, 80 in..lbf) 

    2. Install the 4 wire harness clamps.
  25. CONNECT HEATER WATER INLET HOSE 
  26. INSPECT CYLINDER HEAD SET BOLT  (See REPLACEMENT )
  27. INSTALL CYLINDER HEAD SUB-ASSY  (See REPLACEMENT )
  28. INSTALL CAMSHAFT BEARING NO.2  (See REPLACEMENT )
  29. INSTALL CAMSHAFTS  (See REPLACEMENT - 1GR-FE and REPLACEMENT - 1GR-FE (2WD) )
  30. INSTALL CHAIN TENSIONER ASSY NO.2  (See REPLACEMENT - 1GR-FE and REPLACEMENT - 1GR-FE (2WD) )
  31. INSTALL CAMSHAFT TIMING GEARS AND NO.2 CHAIN (RH BANK)  (See REPLACEMENT )
  32. INSTALL CHAIN VIBRATION DAMPER NO.1  (See REPLACEMENT )
  33. INSTALL WATER BYPASS JOINT RR  (See REPLACEMENT )
  34. INSTALL INTAKE MANIFOLD  (See REPLACEMENT )
  35. INSTALL EXHAUST MANIFOLD SUB-ASSY RH  (See REPLACEMENT )
  36. INSTALL MANIFOLD STAY 
    1. Install the manifold stay with the 6 bolts.

      Torque: 40 N.m (408 kgf.cm, 30 ft.lbf) 

  37. INSTALL EXHAUST PIPE ASSY FRONT  (See Removal & Installation and Disassembly & Reassembly )
  38. INSTALL EXHAUST FRONT PIPE ASSY NO.2  (See Removal & Installation and Disassembly & Reassembly )
  39. INSTALL COOL AIR INLET NO.1 
    1. Install the cool air inlet with the 2 bolts.

      Torque: 12 N.m (122 kgf.cm, 9.0 ft.lbf) 

  40. INSTALL CHAIN TENSIONER SLIPPER 
  41. INSTALL CHAIN TENSIONER ASSY NO.1  (See REPLACEMENT )

    SST 10514

  42. INSTALL CHAIN SUB-ASSY  (See REPLACEMENT )
  43. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSY  (See REPLACEMENT )
  44. INSTALL ENGINE ASSY  (See REPLACEMENT )
  45. INSTALL BATTERY  (See PRECAUTION )
  46. ADD ENGINE COOLANT  (See REPLACEMENT )
  47. ADD ENGINE OIL  (See REPLACEMENT )
  48. CHECK FOR ENGINE COOLANT LEAKAGE  (See ON-VEHICLE INSPECTION )
  49. CHECK FOR ENGINE OIL LEAKAGE 
  50. CHECK FOR FUEL LEAKAGE 
  51. CHECK FOR EXHAUST GAS LEAKAGE 
  52. INSPECT IGNITION TIMING  (See INSPECTION )

    SST 09843-18040

  53. INSPECT ENGINE IDLING SPEED  (See INSPECTION )

    SST 09843-18030

  54. INSPECT CO/HC  (See OVERHAUL )
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