KNOCK SENSOR > INSTALLATION

for Preparation Click here



1. INSTALL KNOCK SENSOR


    A099415E01

  1. Install the sensor so that it is horizontal as shown in the illustration. Then install the bolt.

    Torque:
    20 N*m{ 204 kgf*cm , 15 ft.*lbf }

    HINT:
    It is acceptable for the sensor to be tilted +- 10°.

  1. Connect the sensor connector.



2. INSTALL INTAKE MANIFOLD


    G039042E03

  1. Install a new gasket and the intake manifold with the 5 bolts and 2 nuts.

    Torque:
    25 N*m{ 255 kgf*cm , 18 ft.*lbf }

  1. Connect the VSV hose and connector for EVAP.

  1. Connect the vacuum hose.



3. INSTALL THROTTLE BODY


    G036423E01

  1. Install a new gasket on the intake manifold.

    HINT:
    Align the protrusion of the gasket with the groove of the intake manifold.



    A086829E01

  1. Install the throttle body with the 2 bolts and 2 nuts.

    Torque:
    9.0 N*m{ 92 kgf*cm , 80 ft.*lbf }

  1. Connect the water by-pass hose to the throttle body.

  1. Connector the throttle control motor & throttle position sensor connector.



4. INSTALL STARTER ASSEMBLY


    G039103E03

  1. Install the starter with the 2 bolts.

    Torque:
    37 N*m{ 377 kgf*cm , 27 ft.*lbf }

  1. Install the starter wire to terminal 30 with the nut.

    Torque:
    9.8 N*m{ 100 kgf*cm , 87 in.*lbf }

  1. Connect the starter connector.

  1. Install the clutch release cylinder.



5. INSTALL INTAKE AIR CONNECTOR


6. ADD ENGINE COOLANT

  1. Tighten all the plugs and fill the radiator with TOYOTA Super Long Life Coolant (SLLC).

    Torque:
    24.5 N*m{ 250 kgf*cm , 18 ft.*lbf } for cylinder block drain cock plug

    Standard capacity:
    Item
    		Specified Capacity
    A/T
    		7.3 liters (7.7 US qts, 6.4 lmp. qts)
    M/T
    		7.0 liters (7.4 US qts, 6.2 lmp. qts)

  1. Fill the radiator with TOYOTA Super Long Life Coolant (SLLC) to the F line.

    HINT:
    1. TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, 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).
    2. Please contact your TOYOTA dealer for further details.

      NOTICE:
      Never use water as a substitute for engine coolant.

  1. Press the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.
    If the coolant level drops below the F line, add TOYOTA SLLC to the F line.

  1. Install the radiator cap.

  1. Bleed air from the cooling system.

    1. Warm up the engine until the thermostat opens. While the thermostat is open, circulate the coolant for several minutes.

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

    3. Press the inlet and outlet radiator hoses several times by hand to bleed air.

      CAUTION:
      When pressing the radiator hoses:
      1. Wear protective gloves.
      2. Be careful as the radiator hoses are hot.
      3. Keep your hands away from the radiator fan.

  1. Stop the engine and wait until the coolant cools down to ambient temperature.

    CAUTION:
    Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.



    A112081E01

  1. Check the coolant level in the radiator reservoir.
    If the coolant level is low, add SLLC to the reservoir F line.



7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL


8. PERFORM INITIALIZATION

  1. Perform initialization (Click here).

    NOTICE:
    Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.



9. CHECK FOR ENGINE COOLANT LEAKS

  1. Check for engine coolant leaks (Click here).