Removal and Replacement

Knock sensor (KS), replacing

Removing the knock sensor (KS)





Remove
- the pipe to the control module cover
- the intake manifold between the front cover plate and the air cleaner (ACL) housing
- the cable clamp
- the engine cooling fan (FC) relay
Disconnect the two small connectors from the relay.
Disconnect the connector to the right of the engine cooling fan (FC) relay. Put the wiring to one side.
Disconnect the connectors on the fan shroud nearest the fan and the battery. Then continue with the connector from the evaporative emission system (EVAP) valve
- The evaporative emission system (EVAP) valve and its hose that runs downwards from the upper section of the fan shroud. Put the wiring to one side
- the four screws retaining the fan shroud at the upper edge
Disconnect the connector from the upper right corner of the fan shroud
- the bracket from the upper section of the fan shroud
- the rubber section of the charge air pipe between the throttle body (TB) and radiator
- the two plastic washers/spacers from the fan shroud.




- the large hose from the intake manifold
- the small hoses from the intake manifold

Note! Mark the small hoses before they are disconnected from the intake manifold.

- the small hoses from the hose bracket on the cylinder block (left front)
Disconnect the connectors from the pressure and temperature sensors on the charge air pipe to the throttle body (TB).




Slacken off the clamp on the charge air pipe to the throttle body (TB) at the throttle body (TB).
Push the charge air pipe and cooler out of the way while pulling the fan up.




- the charge air pipe
- the knock sensors (KS)
- the tie strap on the wiring harness
Disconnect the connectors.
Pull the knock sensors (KS) out between the cylinder block and starter motor.

Installing knock sensors (KS)




Install new sensors with screws. Finger tighten
Route the wiring along the outside of the starter motor bracket and clamp.
Align the sensors (looking from the front towards the rear). Cable from sensor cylinder 2= 3 o'clock and from sensor cylinder 4= 6 o'clock.
Tighten the knock sensors (KS) to 20 Nm .
Press the knock sensor (KS) connectors together. Check that the wiring is in the correct position. Clamp if necessary.
Install the charge air pipe. Ensure that the screw in the hose clamp is located between the block and pipe, pointing to the left and is parallel to the cylinder block. Do not over tighten.
Push the charge air pipe and cooler out of the way while pushing the fan down.
Install the wiring.
Install the rubber section of the charge air pipe between the throttle body (TB) and radiator. Tighten the clamp on the charge air pipe at the throttle body (TB).




Connect the connectors to the pressure and temperature sensors on the charge air pipe to the throttle body (TB).

Install
- the small hoses to the hose bracket on the cylinder block (left front)
- the small hoses to the intake manifold as marked
- the large hose to the intake manifold
- the two plastic washers / spacers to the fan shroud
- the four screws retaining the fan shroud at the upper edge
Connect the connector to the upper right corner of the fan shroud
- the pipe to the control module cover
- The evaporative emission system (EVAP) valve and its hose that runs downwards to the upper section of the fan shroud
Connect the evaporative emission system (EVAP) valve connector and the connectors on the fan shroud (closest to the battery and fan).




- the cable clamp
- the two small switches in the relay
- the relay for the engine cooling fan (FC)
- the intake pipe between the front cover plate and the air cleaner (ACL) housing.