Ignition system

IGNITION SYSTEM

IG-1

3. As some tachometers are not compatible with thisignition system, we recommend that you confirmthe compatibility of your unit before use.4. Never allow the tachometer terminals to touchground as it could result in damage to the igniterand/or ignition coil.5. Do not disconnect the battery while the engine isrunning.6. Check that the igniter is properly grounded to thebody.

PRECAUTION1. Do not leave the ignition switch on for more than 10minutes if the engine does not start.

2. With a tachometer connected to the system, con-nect the tester probe of the tachometer to terminalIG(-) of the data link connector 1.

-IGNITION SYSTEM PRECAUTIONIG-2

ELECTRONIC SPARK ADVANCE (ESA)The engine control module (ECM) is programmed with data for optimum ignition timing under alloperating conditions. Using data provided by sensors which monitor various engine functions(rpm, intake air volume, engine coolant temperature, etc.), the ECM triggers the spark at preciselythe right instant.

SYSTEM CIRCUIT

-IGNITION SYSTEM SYSTEM CIRCUITIG-3

PREPARATIONSST (SPECIAL SERVICE TOOLS)

SSM (SPECIAL SERVICE MATERIALS)

RECOMMENDED TOOLS09082-00050 TOYOTA Electrical Tester Set

08826-00080 Seal packing or equivalent

09843-18020 Diagnosis Check Wire

09200-00010 Engine Adjust Kit

EQUIPMENTSpark plug cleaner

Timing light

Tachometer

Ignition coil

-IGNITION SYSTEM PREPARATIONIG-4

ON-VEHICLE INSPECTIONSPARK TESTCHECK THAT SPARK OCCURS(a) Disconnect the high-tension cords from the sparkplugs.(b) Remove the spark plugs.(c) Install the spark plugs to each high-tension cord.(d) Ground the spark plug.(e) Check if spark occurs while engine is being cranked.HINT: To prevent gasoline from being injected frominjectors during this test, crank the engine for no morethan 1 - 2 seconds at a time.If the spark does not occur, perform the test as fol-lows:

CHECK POWER SUPPLY TO IGNITION COILAND IGNITER1. Turn ignition switch to ON.2. Check that there is battery voltage at ignition coilpositive (+) terminal.

CHECK RESISTANCE OF IGNITION COIL(See page IG-8 )Resistance: (Cold) (Hot) Primary 0.36 - 0.55� 0.45 - 0.65� Secondary 9.0 -15.4 k� 11.4 - 18.1 k�

CHECK RESISTANCE OF SIGNAL GENERATOR(PICKUP COIL) (See page IG-8 )Resistance: (Cold) (Hot) NE(+) and NE(-) 370 - 550 � 475 - 650 �

CHECK RESISTANCE OF HIGH-TENSION CORD(See page IG-6 )Maximum resistance: 25 k� per cord

CHECK AIR GAP OF DISTRIBUTOR(See page IG-8 )Air gap: 0.2 - 0.4 mm (0.008 - 0.016 in.)

Check wiring between ECM, distributor andigniter, and then try another ECM.

Check wiring between ignition switch to ignitioncoil and igniter.

CHECK CONNECTION OF IGNITION COIL,IGNITER AND DISTRIBUTOR CONNECTOR

CHECK IGT SIGNAL FROM ECM(See page EG-149 )

Replace the distributor housing assembly.

Replace the distributor housingassembly.

Replace the ignition coil.

TRY ANOTHER IGNITER

Replace the cord(s).

Connect securely.

SPARK TEST

BAD

BAD

BAD

BAD

BAD

BAD

BAD

-IGNITION SYSTEM ON-VEHICLE INSPECTIONIG-5

HIGH-TENSION CORDS INSPECTION1. DISCONNECT HIGH-TENSION CORDS FROMSPARK PLUGSDisconnect the high - tension cords at the rubberboot. Do not pull on the high-tension cords.

NOTICE: Pulling on or bending the cords may damage theconductor inside.

2. REMOVE DISTRIBUTOR CAP WITHOUTDISCONNECTING HIGH-TENSION CORDS3. INSPECT HIGH-TENSION CORD RESISTANCEUsing an ohmmeter, measure the resistance withoutdisconnecting the distributor cap.

Maximum resistance:25 k� per cord

If the resistance is greater than maximum, check theterminals. If necessary, replace the high-tension cordand/or distributor cap.

4. REINSTALL DISTRIBUTOR CAP5. RECONNECT HIGH-TENSION CORDS TO SPARKPLUGS


1. DISCONNECT HIGH-TENSION CORDS FROMSPARK PLUGSDisconnect the high-tension cords at the rubberboot. Do not pull on the high-tension cords.


2. REMOVE SPARK PLUGS

4. VISUALLY INSPECT SPARK PLUGSCheck the spark plug for electrode wear, threaddamage and insulator damage.If abnormal, replace the spark plug.Recommended spark plug:

W16EXR-U1 1 for NDBPR5EY11 for NGK

5. ADJUST ELECTRODE GAPCarefully bend the outer electrode to obtain the cor-rect electrode gap.Correct electrode gap:

1.1 mm (0.043 in.)

6. INSTALL SPARK PLUGSTorque: 18 N-m (180 kgf-cm, 13 ft-lbf )

7. RECONNECT HIGH-TENSION CORDS TO SPARKPLUGS

3. CLEAN SPARK PLUGSUsing a spark plug cleaner or wire brush, clean thespark plug.

SPARK PLUGS INSPECTION


2. INSPECT SIGNAL GENERATOR (PICKUP COIL)RESISTANCEUsing an ohmmeter, measure the resistance betweenthe terminals (NE(+) - NE(-)).

Pickup coil resistance (Cold):370-550 �Pickup coil resistance (Hot):475-650 �

If the resistance is not as specified, replace the distrib-utor housing assembly.3. REMOVE DISTRIBUTOR CAP4. REMOVE DISTRIBUTOR ROTOR5. REMOVE IGNITION COIL DUST COVER

7. INSPECT PRIMARY COIL RESISTANCEUsing an ohmmeter, measure the resistance betweenpositive (+) and negative (-) terminals.

Primary coil resistance (Cold):0.36-0.55 �Primary coil resistance (Hot):0.45 - 0.65 �

If the resistance is not as specified, replace the igni-tion coil.

6. INSPECT AIR GAPUsing a thickness gauge, measure the gap betweenthe 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 distributorhousing assembly.

Ignition Coil

DISTRIBUTOR INSPECTIONNOTICE: ’Cold’ and ’Hot’ in the following sentences ex-press the temperature of the coils themselves. ”Cold” isfrom -10 °C (14°F) to 50°C (122°F) and ”Hot” is from 50°C (122°F) to 100°C (212°F).

1. DISCONNECT DISTRIBUTOR CONNECTORS

Distributor


8. INSPECT SECONDARY COIL RESISTANCEUsing ohmmeter, measure the resistance between thepositive (+) and high-tension terminals.

Secondary coil resistance (Cold):9.0 - 15.4 k�Secondary coil resistance (Hot):11.4 - 18.1 k�

If the resistance is not as specified, replace the igni-tion coil.

9. REINSTALL IGNITION COIL DUST COVER10. REINSTALL DISTRIBUTOR ROTOR11. REINSTALL DISTRIBUTOR CAP12. RECONNECT DISTRIBUTOR CONNECTORS

IGNITER INSPECTION(See procedure Spark Test on page IG-5 )


DISTRIBUTORDISTRIBUTOR REMOVAL1. DISCONNECT NEGATIVE TERMINAL CABLE FROMBATTERY

CAUTION (w/ SRS): Work must be started after 80 sec-onds from the time the ignition switch is turned to the ’LOCK’ position and the negative (-) terminal cable is disconnected from the battery.

2. DISCONNECT DISTRIBUTOR CONNECTORS3. DISCONNECT HIGH-TENSION CORDS FROMSPARK PLUGS(a) Disconnect the cord clamp from the cylinder headcover.(b) Disconnect the 4 high-tension cords from the sparkplugs.Disconnect the high - tension cords at the rubberboot. Do not pull on the high-tension cords.


4. REMOVE DISTRIBUTOR(a) Remove the 2 bolts, and pull out the distributor.(b) Remove the O-ring from the distributor housing.

-IGNITION SYSTEM DISTRIBUTORIG-10

DISTRIBUTOR DISASSEMBLY(See Components for Disassembly and Assembly)1. REMOVE DISTRIBUTOR CAP AND ROTOR2. REMOVE IGNITION COIL DUST COVER3. REMOVE PACKING

4. REMOVE IGNITION COIL(a) Remove the 2 nuts, and disconnect the wires from theterminals of the ignition coil.

COMPONENTS FOR DISASSEMBLY ANDASSEMBLY

-IGNITION SYSTEM DISTRIBUTORIG-1 1

DISTRIBUTOR ASSEMBLY(See Components for Disassembly and Assembly)1. INSTALL DISTRIBUTOR WIRE(a) Connect the connector to the condenser, and installthe wire.(b) Install the grommet of the wire to the housing.

2. INSTALL IGNITION COIL(a) Remove any old packing (FIPG) material.(b) Apply seal packing to the ignition coil installing sur-face of the housing as shown in the illustration.

Seal packing:Part No. 08826-00080 or equivalent

DISTRIBUTOR INSPECTIONINSPECT SHAFTTurn the shaft, and check that it is not rough or worn.If it feels rough or worn, replace the distributor hous-ing assembly.

5. REMOVE DISTRIBUTOR WIRE(a) Remove the grommet of wire to the housing.(b) Disconnect the connector from the condenser, andremove the wire.

(b) Remove the 4 screws and ignition coil.


NOTICE:

• When connecting the wires to the ignition coil,insert both properly into their grooves found on theside of the ignition coil.

• Be sure that the wires do not come into contact withthe signal rotor distributor housing.

4. INSTALL NEW PACKING5. INSTALL IGNITION COIL DUST COVER6. INSTALL ROTOR AND DISTRIBUTOR CAP(a) Install the rotor.(b) Install the cap and condenser with the 3 bolts.

(d) Connect the 2 wires to the terminals of the ignitioncoil with the 2 nuts as shown.

(c) Install the ignition coil with the 4 screws.


DISTRIBUTOR INSTALLATION1. SET NO.1 CYLINDER TO TDC/COMPRESSIONTurn the crankshaft clockwise, and position the slits(A) and indentation (B) of the camshaft as shown in the illustration.

(d) Insert the distributor, aligning the protrusion of theflange with that of the nut on the cylinder head cover.(e) Lightly tighten the 2 bolts.

2. INSTALL DISTRIBUTOR(a) Install a new O-ring to the distributor housing.(b) Apply a light coat of engine oil on the O-ring.

(c) Align the protrusion on the housing with groove of thecoupling.


3. .CONNECT HIGH-TENSION CORDS TO SPARKPLUGS

Firing order:1-3-4-2

4. CONNECT DISTRIBUTOR CONNECTORS5. CONNECT NEGATIVE TERMINAL CABLE TOBATTERY6. WARM UP ENGINEAllow the engine to warm up to normal operatingtemperature.7. CONNECT TACHOMETERConnect the tester probe of a tachometer to terminalIG(-) of the data link connector 1.

NOTICE:

• Never allow the tachometer terminal to touchground as it could reselt in damage to the igniterand/or ignition coil.

• As some tachometers are not compatible with thisignition system, we recommend that you confirmthe compatibility of your unit before use.

8. ADJUST IGNITION TIMING(a) Using SST, connect terminals TE1 and E1 of the datalink connector 1.SST 09843-18020(b) Check the idle speed.

Idle speed:M/T750 ± 50 rpmA/T800 ± 50 rpm(w/ Cooling fan OFF and transmission in neutralposition)

(c) Using a timing light, check the ignition timing.Ignition timing:10� BTDC @ idle(w/ Cooling fan OFF and transmission in neutralposition)

(d) Loosen the 2 bolts, and adjust by turning the distribu-tor.(e) Tighten the 2 bolts, and recheck the ignition timing.

Torque: 17 N-m (175 kgf-cm, 13 ft-lbf)

(f) Remove the SST from the data link connector 1.SST 09843-18020


9. FURTHER CHECK IGNITION TIMINGCheck the ignition timing advance.

Ignition timing:7 - 17� BTDC @ idle(w/ Cooling fan OFF and transmission in neutralposition)

HINT: The timing mark moves in a tange between 7�and 17�.

10. DISCONNECT TACHOMETER AND TIMING LIGHTFROM ENGINE


SERVICE SPECIFICATIONSSERVICE DATA

0.2 - 0.4 mm (0.008 - 0.016 in.)370 - 550�

475 - 650�

Air gapPickup coil resistance (NE(+) - NE(-)

0.36 - 0.55�0.45 - 0.65�9.0 - 15.4 k�11.4 - 18.1 k�

TORQUE SPECIFICATIONS

W16EXR-U1 1BPR5EY11

1.1 mm (0.043 in.)

w/ Terminals TE1 and E1 connected of DLC1

at coldat hotat coldat hot

Spark plug x Cylinder head

Distributor x Cylinder head

High-tensioncord

Recommended spark plug

Secondary coil resistance

Primary coil resistance

Correct electrode gap

10° BTDC @ idle

25 k� per cord

Ignition timing

1-3-4-2

at cold

at hot

Part tightened

Ignition coil

Firing order

Spark plug

Distributor

Resistance

NDNGK

kgf-cm

Limit

ft-lbf

180

175

N-m

-IGNITION SYSTEM SERVICE SPECIFICATIONSIG-17

Business

Ignition system