Knock Sensor: Service and Repair
REPLACING KNOCK SENSORSpecial Tools: 999 5533 (5), 999 5474
Preparations
Remove:
- Battery negative lead.
- Throttle pulley cover.
- Throttle cable.
- Spark plug cover.
- Crankcase ventilation from the cylinder head.
Removing Fuel Rail With Injectors
Remove:
- Fuel rail cover
- Injector connectors
- Fuel line clips (2) and fuel rail mounting screws (2)
- Install the five holders 999 5533 on injectors.
- Remove the clip to the vacuum pipe from the pressure regulator.
- Put a tie strap around delivery line and injector 1 holder to prevent them twisting and leaking fuel.
- Carefully lift up injectors and fuel rail and place on a protective cover on top of engine.
NOTE! Handle injectors carefully to avoid damage to nozzles and needles.
Removing hoses and Connectors
Remove:
- Front charge air pipe.
- Air Cleaner (ACL) inlet hose.
- Canister Purge (CP) Valve hose at Intake manifold.
- Pipe from pressure regulator and place on top of engine.
- Air duct to control module box.
- Vacuum hose to Pulsed Secondary Air Injection System (PAIR) Solenoid Valve.
- Hose to Turbocharger (TC) Control Valve from intake manifold.
- Hose to crankcase ventilation from front edge of intake manifold.
- Idle Air Control (IAC) Valve and Throttle Position (TP) Sensor connectors.
- Brake system servo hose.
- Injector cable harness clip.
Removing Intake Manifold
Remove:
- Upper intake manifold screws (3).
- Dipstick from intake manifold.
- Lower intake manifold screws.
- Intake manifold support bracket screw.
- Intake manifold by lifting it approx. 20 mm, to release intake manifold from engine.
Removing Knock Sensors
Remove:
- The large hose on the flame trap.
- Knock Sensor (KS) connector.
- Knock Sensors (KS).
Installing Knock Sensors
Install:
- Knock sensors (KS) and tighten.
Tightening torques 20 Nm (14.76 ft.lb).
NOTE! Front knock sensor (KS) must be tightened in the 3 o'clock position and rear knock sensor (KS) in the half-past five position.
- Knock sensor (KS) connector.
- Flame trap hose.
Installing Intake Manifold
Install:
- New gasket with four lower manifold screws.
- Intake manifold.
Note! Ensure that crankcase ventilation hose is not trapped between cylinder head and intake manifold when tightening.
- Three upper intake manifold screws.
Tighten all screws to 20 Nm (14.76 ft.Ib).
- Support bracket.
- Dipstick.
Installing Fuel Rail
Install:
- Pipe from pressure regulator.
- Fuel rail and two fuel line clamps, press clip holding the pipe from the pressure regulator into place.
- New screws and tighten.
Tightening torques 10 Nm (7.38 ft.lb).
- Remove injector holders.
- Injector connectors. Check that each connector is fitted with a rubber seal.
- Injector cable harness clip.
- Fuel rail cover.
Reinstalling Hoses and Connectors
Install:
- Idle air control (IAC) valve and throttle position (TP) sensor connectors.
- Brake system servo hose.
- Turbocharger (TC) control valve hose to intake mani fold.
- Canister purge (CP) valve hose.
- Vacuum hose to pulsed secondary air injection system (PAIR) solenoid valve.
- Hose for crankcase ventilation to intake manifold.
- Front charge air pipe.
Installing
Install:
- Air cleaner (ACL) inlet hose.
- Throttle cable.
- Throttle pulley cover.
- Batery negative lead.
- Crankcase ventilation to cylinder head, use new clamp.
- Spark plug cover.
- Air duct to control module box.