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Knock Sensor, Intake Manifold: Installation

  1. INSTALL KNOCK CONTROL SENSOR 
    1. Install the knock control sensor with the bolt.

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

      NOTE: Make sure that the knock sensor is at the correct angle when installing.
    2. Connect the knock control sensor connector.
      Fig 1: Installing Knock Control Sensor With Bolt
      G04407924Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. 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 2: Installing Intake Manifold With Bolts & Nuts
      G04407929Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the engine wire harness to the relay block.
    4. Install the nut shown in Fig 3.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

    5. Connect the 3 connectors.
      Fig 3: Connecting Engine Wire Harness Nut To Relay Block
      G04407930Courtesy 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 4: Installing Harness Clamp Bracket With Bolt
      G04407931Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    11. Connect the ventilation hose No. 3.
      Fig 5: Connecting Ventilation Hose No. 3
      G04407932Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    12. Connect the water by-pass hose No. 2.
      Fig 6: Connecting Water By-Pass Hose No. 2
      G04407933Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    13. Install the clamp bracket with the bolt.

      Torque: 19 N*m (194 kgf*cm, 14 in.*lbf) 

      Fig 7: Installing Clamp Bracket With Bolt
      G04407934Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    14. Connect the vacuum hose.
      Fig 8: Connecting Vacuum Hose
      G04407935Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    15. Connect the fuel vapor feed hose to the VSV.
  3. CONNECT FUEL HOSE (See  INSTALLATION  ) 
  4. CONNECT FUEL HOSE NO.2 (See  INSTALLATION  ) 
  5. INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY (See  INSTALLATION   ) 
  6. INSTALL INTAKE AIR CONNECTOR (See  INSTALLATION   ) 
    Fig 9: Connecting Fuel Vapor Feed Hose To VSV
    G04407936Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 

    Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf) 

  8. ADD ENGINE COOLANT (See  COOLANT  ) 
  9. CHECK FOR ENGINE COOLANT LEAKAGE (See  ON-VEHICLE INSPECTION  ) 
  10. CHECK FOR FUEL LEAKAGE 
  11. INSTALL ENGINE UNDER COVER SUB-ASSEMBLY NO.1 (for 4WD and Pre-Runner)