IGNITION SYSTEM DESCRIPTION PRECAUTION OPERATION -- PREPARATION ‘SERVICE SPECIFICATIONS1G-2 DESCRIPTION The ECU is programmed with data for optimum ignition timing under all operating conditions. data provided by sensors which monitor various angina functions (rpm, intake air valume. temperature, etc.), the microcomputer (ECU) triggers the spark at precisely the right IGNITION SYSTEM — DESCRIPTION Engine {@ ECT) ECU High-Tension Cord 7 Igniter exesIGNITION SYSTEM — DESCRIPTION Distributor ‘with Ignition Coil) Engine (& ECT) ECU {for RHD) Engine (& ECT) ECU for LHD} / Bite Spark Plug MAIN FL 2.0L ‘The ECU monitors the engine condition by signals from each senser, calculates the ignition timing and sends an ignition signal to the igniter. High voltage from the ignition is distributed to each ‘spark plug in the appropriate order to generate a spark between the electrodes, which ignites the sir—fuel mixture. IGNITER ‘The igniter temporarily interrupts the primary currant with the ignition signal (|GT signal) from the ECU and generates sparks at the epark plug. Also, as a fall—safe measure, when ignition occurs an ignition confirmation signal (IGF signal) is sent to the ECU. IGNITION COM The Ignition coil uses a closed core coil with the primary coil wrapped around the core and the ‘secondary coil wrapped around the primary coil. This allows the generation of a high voltage sufficient to cause a spark to jump across the spark plug gap. DISTRIBUTOR This correctly distributes high voltage to the spark plug of each cylinder in the specified ignition order. PICKUP COILS The NE coil detects the crankshaft angle, and the G coil detects camshaft angle.16-4 IGNITION SYSTEM — PRECAUTION. PRECAUTION Do not leave the ignition switch ON for more Than 10 minutes if the engine does not start. With e tachometer connected to the system, con- nect the tester probe of the tachometer to terminal 1GO of the check connector. ‘As some tachometers are not compatible with this Ignition system, we recommend that you confirm the compatibility of your unit before use. Never allow the tachometor terminsls to touch ground as It could resuit in damage to the igniter ‘and/or ignition coll. Do not disconnect the battery while the engine Is running. Check that the Igniter Is properly grounded to the body.IGNITION SYSTEM — OPERATION lee SYSTEM CIRCUIT Ignition Switch Distributor with Ignition Coil NEG IGT IGF Engine (& ECT) ECU OPERATION To maintain the most appropriate ignition timing, the ECU sends a control signal so that the igniter sends current to the ignition coll and the spark plugs produce a spark.16-8 PREPARATION SST (SPECIAL SERVICE TOOLS) IGNITION SYSTEM — PREPARATION. P (8185-16100 Spark Plug Wrench = (09643-18020 Dingnosis Check Wire RECOMMENDED TOOLS Sz 00082-OIEO TOYOTA Buel Taxor Sr aS (08200-00010 Engine Adjust Kit =~ EQUIPMENT ‘Megger insulation resistance meter Tnaulaton resistance meter ‘Spark plug cleaner ‘Tachometer Timing light Taniton timing SSM (SPECIAL SERVICE MATERIALS) "08826-00080 Seal pecking oF equivalat Taniton coi\G-7 IGNITION SYSTEM — ON-VEHICLE INSPECTION ON—VEHICLE INSPECTION SPARK TEST CHECK THAT SPARK OCCURS (2) Disconnect the high—tension cords from the spark plugs. (b) Remove the spark plugs. . (c) Install the spark plugs to the each high—tension cord. (@) Ground the spark plug. (@) Check if spark occurs while engine is being cranked. HINT: To prevent gasoline from being injected from injectors during this test, crank the engins for no more than 1 — 2 seconds at a time. if the spark does not occur. perform the test as fol- lows: ‘SPARK TEST Tho ‘CHECK CONNECTION OF DISTRIBUTOR AND Connect securely IGNITER CONNECTORS ‘BAD TOK ‘GHECK RESISTANCE OF HIGH-TENSION CORD Replace the corde). (See page 1G-8 =n Maximum resistance: 25 k0 per cord Tox ‘CHECK POWER SUPPLY TO IGNITION COM Check the wiring between igrition switch and 4. Tum ignition switch ON. ignition colt 2. Check that there is battery voltage at ignition coil [SAD Positive (+) eerminol. OK ‘CHECK RESISTANCE OF IGNITION CON Replace the ignition col {See page1G-10) Resiatance: Cold Hot ° Primary 038-0552 0.45 -0.85.0 ad Secondary 20-154K2 _11.4~18.1k0 Jo ‘CHECK RESISTANCE OF SIGNAL GENERATOR Replace the distributor housing assembly. (PICKUP COIL) {S00 page1G-11) Rosistance: Gold Hot ‘BAD G@andGS w5-275N 240-3250 NE@ and NE® 370-5800 475650. ‘OK CHECK AIR GAP OF DISTRIBUTOR Replace the distributor housing {See pege I-10) — Air gap: 02-04 mm 10.008 - 0.016 in.) BA Tox ‘CHECK IGT SIGNAL FROM ECU Check the wiring between ECU distributor and {See page EG-191) BAD"|_ igniter, and then try another ECU. To« “TRY ANOTHER IGNITERIGNITION SYSTEM — ON—VEHICLE INSPECTION HIGH—TENSION CORDS INSPECTION 1, REMOVE HIGH—TENSION CORDS Disconnect the high — tension cords at the rubber boot, Do not pull on the cords. NOTICE: Pulling on or bending the cords may damage the conduetor inside. 2. INSPECT HIGH—TENSION CORD RESISTANCE Using an ohmmeter, measure the resistance. Maximum resistance: 25 kQ per cord {f the resistance is greater than maximum, replace the high—tension cord. 3. REINSTALL HIGH—TENSION CORDS SPARK PLUGS INSPECTION 1. DISCONNECT HIGH — TENSION CORDS FROM SPARK PLUGS Disconnect the high— tension cords at the rubber boot. Do not pull on the high—tension cords. NOTICE: Pulling on or bending the cords may damage the conductor inside. 2. REMOVE SPARK PLUGS: Using SST, remove the 4 spark plugs. SST 09155-16100IGNITION SYSTEM — ON—VEHICLE INSPECTION ies 3. . GLEAN SPARK PLUGS Using @ spark plug cleaner or wire brush, clean the spark plug. 4, VISUALLY INSPECT SPARK PLUGS Check the spark plug for electrode wear, thread damage and insulator damage. {f abnormal, replace the spark plug. Recommended spark plug: K20R—UST for ND BKRGEYAIT for NGK rene, 5. ADJUST ELECTRODE GAP Carefully bend the outer electrode to obtain the cor- 9 rect electrode gap. te Electrode gap: 1.1 mm (0.043 In.) S S 8. REINSTALL SPARK PLUGS Using SST, install the 4 spark plugs. SST 08155-16100 Torque: 18 Nm (180 kof-em, 13 ftdbf) 7. RECONNECT HIGH—TENSION CORDS TO SPARK PLUGS.NITION SYSTEM VEHICLE INSPECTION DISTRIBUTOR INSPECTION NOTICE: “Cold” and “Hot” in the following sentences express the temperatura of the colls themselves. “Cold ie from — 10°C (14°F) to 50°C (122"F) and “Hot” is from 80°C (12°F) to 100°C (212"F). 1. DISCONNECT DISTRIBUTOR CONNECTORS 2. REMOVE DISTRIBUTOR CAP 3. REMOVE ROTOR 4, REMOVE IGNITION COIL DUST COVER Ignition Coil 5. INSPECT PRIMARY COIL RESISTANCE Using an ohmmeter, measure the resistance between the-positive (+) and negative (—) terminals. Primary coil resistono: Cold 0.38 — 0.56 0 Het 0.45 — 0.65 0 {f the resistance is not as specified, replace the igni- tion coil. 6. INSPECT SECONDARY COIL RESISTANCE Using an ohmmeter, measure the resistance between positive (+) and high—tension terminals. ‘Secondary coil resistance: Cold 9.0 — 15.40 Hot 114 — 18.1 ko if the resistance is not as specified, replace the tion ooil. Distributor 7. INSPECT AIR GAP Using a feeler gauge. measure the air gap between the signal rotor and pickup coil projection. ‘Air gap: 0,2 — 0.4 mm (0.008 — 0.016 in) If the air gap is not as specified, replace the distributor housing assembly.IGNITION SYSTEM —-ON- VEHICLE INSPECTION jon 8, INSPECT SIGNAL GENERATOR (PICKUP COIL) RESISTANCE Using an ohmmeter, measure the resistance between + the terminals. G® and GO 188 - 278.0 NE® and NEO 370 - 5609 Hot G® and GO 240 ~ 3250 NE® and NEO 475 — 6500 If the resistance is not as specified, replace the distrib- tutor housing assembly. 9. REINSTALL IGNITION COIL DUST COVER 10. REINSTALL ROTOR 11. REINSTALL DISTRIBUTOR CAP 12, RECONNECT DISTRIBUTOR CONNECTORS IGNITER INSPECTION = (See procedure Sperk Test on page IG —7)16-12 IGNITION SYSTEM — DISTRIBUTOR. DISTRIBUTOR COMPONENTS FOR DISASSEMBLY AND ASSEMBLY 4 Non-rausable port Condenser Dietributor Wire {ignition Coit Dust Cover Distributor Cap {with High-Tension Cord DISTRIBUTOR DISASSEMBLY (See Components for Disassembly and Assembly) 1. REMOVE DISTRIBUTOR CAP Remove the 3 bolts and distributor cap. 2. REMOVE ROTOR 3. REMOVE IGNITION COIL DUST COVER (2) Remove the dust cover. {b) Remove the packing.IGNITION SYSTEM — DISTRIBUTOR lois 4, REMOVE DISTRIBUTOR WIRE {2) Remove the 2 nuts, and disconnect the 3 wires from ‘the ignition coil terminals. (b) Remove the distributor wire from the distributor hous- ing. 8. REMOVE IGNITION COIL Remove the 4 screws and ignition coil. 6. REMOVE CONDENSER Remove the screw and condenser. DISTRIBUTOR INSPECTION INSPECT SHAFT ‘Turn the shaft and check that it is not rough or worn. If it feels rough or worn, replace the distributor hous- ing assembly.16-14 IGNITION SYSTEM — DISTRIBUTOR DISTRIBUTOR ASSEMBLY (See Components for Disassembly and Assembiy) 1, INSTALL CONDENSER Install the condenser with tha scraw. 2. INSTALL IGNITION COIL (2) Remove any old packing (FIPG) material. {b) Apply seal packing to the ignition coil installing sur- faca of the housing. ‘Seal pecking: Part No. 08826-00080 or equivalent (c}_ Install the ignition coil with the 4 screws. 3. INSTALL DISTRIBUTOR WIRE (a) . Install the grommet of the wire to the distributor housing. (b) Connect the 3 wires ta the ignition coil terminals with ‘the 2 nuts.IGNITION SYSTEM — DISTRIBUTOR 8 NOTICE: © When connecting the wires to the ignition coil, Insert both properly inta their grooves found on the side of the ignition coil. © Be sure the wires do not contact with the signal rotor or distributor housing. . INSTALL IGNITION COIL DUST COVER (a) Install a new packing to the distributor housing. {b) Install the dust cover. 5. INSTALL ROTOR 6. INSTALL DISTRIBUTOR CAP AND HIGH—TENSION CORDS Install the distributor cap with the 3 bolts.16-16 1 @ @) ©) @ fo) IGNITION SYSTEM — DISTRIBUTOR. DISTRIBUTOR INSTALLATION SET NQ.1 CYLINDER TO TOC/COMPRESSION ‘Turn the crankshaft clockwise, and position the slit of ‘the intake camshaft as shown in the illustration. INSTALL DISTRIBUTOR Install a new O—ring to the housing. Apply a light coat of engine oil on the O-ring Align the cutout portion of the coupfing with the protrusion of tha housing. Insert the distributor, aligning the center of the flange with that of the bolt hole on the cylinder head. Lightly tighten the 2 bolts.~___IGNITION SYSTEM — DISTRIBUTOR ie? 3. CONNECT HIGH—TENSION CORDS TO SPARK PLUGS (@) Connect the 4 high—tension cords to the spark plugs. Firing order: 1-3-4-2 (b) Connect the 4 high—tension cords to the clamp on the cylinder head cover. 4, CONNECT DISTRIBUTOR CONNECTORS 5. ADJUST IGNITION TIMING (See page EG—25) Ignition timing: 10° BTDC @ idle (w/ Terminals TE1 and £1 connected)Ic-18 IGNITION SYSTEM — SERVICE SPECIFICATIONS SERVICE SPECIFICATIONS SERVICE DATA = Toation wing | w/ Terminale TEI and El connected 1 TOC O ie Feng order = To3-4-2 High=tenaian | Rvistanoe Timi | 250 per cord cord Spark plug | Recommended soak sua wo | KOR =UTT nox } BKREEYAIY Sect oP 1.1 mm (0.049 in) Primary col redstance wood | 038 058 0 thot | 045 0850 Secondary co resistance stools | 80 18440 sthot | 11410440 Dinsier | Ar oa 02 — 04 mm 2008 — 6616 Im) Pickup coll resistance: steod GH-GO | 186-2750 NE® — NEO | 370-6500 athot GB-GO | 240-3250 NE® — NEO | 475 - 6500 TORQUE SPECIFICATIONS Part tightened Nm kgfom ftlbt Spark plug x Cylinder head 18 180° 13 Ditibvor x Orinda heed m 195 1