2008 Toyota Prius TouringFACTORY OEM SERVICE PROCEDURE

Knock Sensor: Installation

  1. INSTALL KNOCK SENSOR 
    1. Install the knock sensor with the nut.

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

      NOTE: Be careful to install the knock sensor in the correct direction.
    2. Connect the knock sensor connector.
      Fig 1: Tightening Torque Of Knock Sensor Nut
      G05674412Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL INTAKE MANIFOLD 
    1. Install a new gasket to the cylinder head.
      Fig 2: Locating Cylinder Head Gasket
      G05189026Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the intake manifold with the 3 bolts and 2 nuts.

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

    3. Install the No. 1 fuel vapor feed hose to the hose clamp.
      Fig 3: Locating Intake Manifold Bolts And Nuts
      G05189025Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the harness clamp bracket with the bolt.

      Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 

    5. Install the connector clamp.
    6. Install the 3 wire harness clamps.
      Fig 4: Locating Wire Harness Clamps
      G05189024Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Connect the throttle position sensor connector.
    8. Connect the throttle control motor connector.
      Fig 5: Locating Throttle Position Sensor Connector
      G05189005Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Connect the No. 2 water by-pass hose.
    10. Connect the water by-pass hose.
      Fig 6: Locating No. 2 Water By-Pass Hose
      G05189004Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    11. Connect the No. 1 fuel vapor feed hose.
    12. Connect the No. 2 ventilation hose.
    13. Connect the ventilation hose.
      Fig 7: Locating No. 1 Fuel Vapor Feed Hose
      G05189003Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL OIL DIPSTICK GUIDE 
    1. Apply a light coat of engine oil to a new O-ring and install it to the dipstick guide.
      Fig 8: Identifying O-ring
      G05189037Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the dipstick guide with the bolt.

      Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 

      NOTE: Be careful that the O-ring is not cracked or jammed when installing it.
    3. Connect the wire harness clamp.
    4. Install the dipstick.
  4. INSTALL AIR CLEANER ASSEMBLY  (See INSPECTION  )
    Fig 9: Locating Wire Harness Clamp
    G05189020Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  6. ADD ENGINE COOLANT  (See COOLANT )
  7. INSPECT FOR COOLANT LEAK (for Engine)  (See ON-VEHICLE INSPECTION )
  8. INSTALL ENGINE UNDER COVER LH 
  9. INSTALL RADIATOR SUPPORT OPENING COVER  (See INSPECTION  )
  10. PERFORM INITIALIZATION 
    1. Perform initialization (see INITIALIZATION ).
      NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.