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

DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
REMOVE ENGINE UNDER COVER SUB-ASSY NO.1 (PRE RUNNER AND 4WD TYPE)
DRAIN ENGINE COOLANT (See REPLACEMENT )
REMOVE INTAKE AIR CONNECTOR (See REPLACEMENT )
REMOVE THROTTLE W/MOTOR BODY ASSY (See REPLACEMENT )
DISCONNECT FUEL HOSE (See REPLACEMENT )
DISCONNECT FUEL HOSE NO.2 (See REPLACEMENT )
REMOVE INTAKE MANIFOLD
1. Disconnect the fuel vapor feed hose from the VSV.
  
  Fig 1: Disconnecting Fuel Vapor Feed Hose From VSV
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Disconnect the vacuum hose.
  
  Fig 2: Disconnecting Vacuum Hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the bolt, then remove the clamp bracket.
  
  Fig 3: Removing Bolt And Clamp Bracket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Disconnect the water bypass hose No. 2.
  
  Fig 4: Disconnecting Water By-Pass Hose No.2
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Disconnect the ventilation hose No. 3.
  
  Fig 5: Disconnecting Ventilation Hose No.2
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Disconnect the VSV connector.
7. Disengage the engine wire harness clamp.
8. Disconnect the compressor magnetic clutch connector.
  (w/AIR CONDITIONING)
9. Disengage the wire harness clamp.
10. Remove the bolt and harness clamp bracket.
  
  Fig 6: Disconnecting VSV Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. Disconnect the 3 connectors.
12. Remove the nut shown in the illustration.
13. Disconnect the engine wire harness from the relay block.
  
  Fig 7: Removing Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
14. Remove the 5 bolts and 2 nuts, then remove the intake manifold.
  
  Fig 8: Removing 5 Bolts And 2 Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE KNOCK CONTROL SENSOR
1. Disconnect the knock control sensor connector.
2. Remove the bolt, then remove the knock control sensor.
  
  Fig 9: Disconnecting Knock Control Sensor Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL KNOCK CONTROL SENSOR
1. Install the knock control sensor with the bolt.
  Torque: 20 N.m (204 kgf.cm, 15 ft.lbf)
  
  Make sure that the knock sensor is at the correct angle when installing.
2. Connect the knock control sensor connector.
  
  Fig 10: Identifying Knock Sensor Correct Angle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL INTAKE MANIFOLD
1. Install a new gasket onto the intake manifold.
2. Install the intake manifold with the 5 bolts and 2 nuts.
  Torque: 25 N.m (255 kgf.cm, 18 ft.lbf)
  
  Fig 11: Installing Intake Manifold With Bolts And Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Connect the engine wire harness to the relay block.
4. Install the nut shown in the illustration.
  Torque: 10 N.m (102 kgf.cm, 7 ft.lbf)
5. Connect the 3 connectors.
  
  Fig 12: Installing Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Install the harness clamp bracket with the bolt.
  Torque: 8.2 N.m (84 kgf.cm, 73 in..lbf)
7. Engage the wire harness clamp.
8. Connect the compressor magnetic clutch connector.
  (w/AIR CONDITIONING)
9. Engage the engine wire harness clamp.
10. Connect the VSV connector.
  
  Fig 13: Connecting VSV Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. Connect the ventilation hose No. 3.
  
  Fig 14: Connecting Ventilation Hose No.2
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. Connect the water bypass hose No. 2.
  
  Fig 15: Connecting Water By-Pass Hose No.2
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
13. Install the clamp bracket with the bolt.
  Torque: 19 N.m (194 kgf.cm, 14 in..lbf)
  
  Fig 16: Installing Clamp Bracket With Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
14. Connect the vacuum hose.
  
  Fig 17: Connecting Vacuum Hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
15. Connect the fuel vapor feed hose to the VSV.
  
  Fig 18: Connecting Fuel Vapor Feed Hose To VSV
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT FUEL HOSE (See REPLACEMENT )
CONNECT FUEL HOSE NO.2 (See REPLACEMENT )
INSTALL THROTTLE W/MOTOR BODY ASSY (See REPLACEMENT )
INSTALL INTAKE AIR CONNECTOR (See REPLACEMENT )
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See PRECAUTION )
Torque: 3.9 N.m (40 kgf.cm, 35 in..lbf)
ADD ENGINE COOLANT (See REPLACEMENT )
CHECK FOR ENGINE COOLANT LEAKAGE (See ON-VEHICLE INSPECTION )
CHECK FOR FUEL LEAKAGE (See ON-VEHICLE INSPECTION )
INSTALL ENGINE UNDER COVER SUB-ASSY NO.1 (PRE RUNNER AND 4WD TYPE)