Engine Controls - Remove/install/overhaul Toyota Camry V30

INTRODUCTION

Removal, overhaul and installation procedures are covered in this article. If component removal and installation is primarily an unbolt and bolt-on procedure, only a torque specification may be furnished.

DISTRIBUTOR

Note. For timing specifications and procedures, see ADJUSTMENTS article in the ENGINE PERFORMANCE Section.

Removal (2.2L 5S-FE)

1. Disconnect battery negative cable. Disconnect throttle cable from linkage on throttle body. Disconnect air temperature sensor connector and cruise control cable clamp from air cleaner housing. Remove duct hose from throttle body.
2. Remove air cleaner top housing. Disconnect spark plug wires from spark plugs. Disconnect distributor electrical connector. Remove 2 distributor hold-down bolts. Remove distributor. Remove "O" ring from distributor housing and discard.

Ignition coil, condenser, rotor, and harness connector are serviceable. Pick-up coil and distributor housing assembly are replaced as a unit. When replacing ignition coil, ensure seal packing is applied to housing-to-coil contact surface. When installing coil wires, ensure wires are properly inserted into grooves on side of coil.

Installation

1. Set cylinder No. 1 to TDC of compression stroke. Camshaft slot should be in vertical position. Coat NEW "O" ring lightly with oil and install onto distributor housing. Align cutout mark on distributor drive coupling with line on distributor housing. (Scheme 1)
2. Install distributor, aligning distributor flange mounting holes with bolt holes on cylinder head. Install and snug distributor hold-down bolts. Connect distributor electrical connector. Install spark plug wires.
3. To complete installation, reverse removal procedures. Connect battery negative cable. Start engine and set ignition timing. Tighten distributor hold-down bolts to 14 ft. lbs. (19 N.m).

Removal (3.0L 3VZ-FE)

1. Disconnect battery negative cable. Remove airflow meter connector. Remove vacuum hoses from air cleaner hose. Remove air cleaner cap, airflow meter, and air cleaner hose as an assembly.
2. Record spark plug wire locations in distributor cap. Using screw driver, disconnect spark plug wire caps from distributor cap. Disconnect distributor electrical connector. Remove 2 distributor hold-down bolts. Remove distributor. Remove "O" ring from distributor housing and discard.

Only distributor cap and rotor are serviceable. Pick-up coil and distributor housing assembly are replaced as a unit.

1. Set cylinder No. 1 to TDC of compression stroke. Camshaft slot should be perpendicular to cylinder head. Coat NEW "O" ring lightly with oil and install onto distributor housing. Align cutout mark on distributor drive coupling with line on distributor housing. (Scheme 1)
2. Install distributor, aligning raised line on housing with distributor bearing cap cutout. Connect distributor electrical connector. Install spark plug wires. Install air cleaner cap, airflow meter and air cleaner hose assembly. Install vacuum hoses to duct. Connect airflow meter connector. Connect battery negative cable. Start engine and set ignition timing. Tighten distributor hold-down bolts to 13 ft. lbs. (18 N.m).

Scheme 1

FUEL SYSTEM PRESSURE RELEASE

Disconnect battery negative cable. If possible, position container under fuel fitting to be loosened. To prevent fuel spraying, use a rag to cover fuel fitting to be loosened. Slowly loosen fitting, allowing pressurized fuel to spill into container or spray into rag(s). After fuel system pressure is released, disconnect fitting and plug all openings.

COLD START VALVE

Component removal and installation is primarily a locate, unbolt/remove, and bolt-on procedure. Mounting bolt(s) and fuel pipe bolt torque specifications are furnished. See appropriate TORQUE SPECIFICATIONS table at end of article.

Removal & Installation

1. Disconnect battery negative cable. Remove gas cap from filler tube to relieve fuel tank air pressure. Release fuel pressure at fuel filter. See «FUEL SYSTEM PRESSURE RELEASE»(/toyota/camry/v30-1990-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release) . Remove rear seat bottom cushion. Disconnect fuel pump and fuel sender electrical connectors at floor service hole cover.
2. Remove service hole cover. Disconnect harness connector from fuel pump/sender unit. Disconnect fuel line fitting and hoses from pump/sender unit. Remove attaching screws or bolts from pump/sender unit. Remove pump/sender unit from tank and remove from vehicle.
3. Remove harness connector at fuel pump. Remove pump hose clamps. Remove pump from bracket. Using small blade screwdriver, remove clip retaining pump filter.
4. To install, reverse removal procedure. Use NEW retaining clip to install filter. Use NEW gasket between pump/sender bracket and tank. Tighten fuel pump bracket-to-tank nuts to 35 INCH lbs. (3.9 N.m).

FUEL INJECTORS & FUEL RAILS

Note. Install NEW grommets and "O" rings when replacing fuel injectors or reinstalling old injectors. Ensure injectors rotate smoothly in injector ports and in fuel rail. If injectors DO NOT rotate smoothly, check "O" rings for proper installation.

1. Disconnect battery negative cable. Release fuel pressure at fuel filter. See «FUEL SYSTEM PRESSURE RELEASE»(/toyota/camry/v30-1990-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release) . Drain engine coolant. Disconnect throttle cable(s) from throttle body. Remove air temperature sensor connector and cruise control cable clamp from air cleaner housing.
2. Loosen duct hose clamp from throttle body. Remove air cleaner cap, resonator and duct hose as an assembly. Disconnect TPS connector and ISC valve connector from throttle body. Mark positions of all vacuum hoses connected to throttle body for reassembly purposes. Remove vacuum hoses from throttle body.
3. Remove 4 throttle body mounting bolts. Remove coolant hoses from throttle body and remove throttle body. Remove power steering vacuum hoses from tubing lines near intake manifold. Mark positions and remove 2 vacuum hoses from EVAP BVSV near distributor. Remove EGR temperature sensor harness connector (if equipped).
4. Mark positions and remove 2 vacuum hoses from EGR VSV near bottom of intake manifold. Remove vacuum hose from canister. Remove vacuum hoses tubing retaining clamp near bottom of intake manifold. Disconnect EGR pipe fittings. Remove EGR valve, EGR modulator and related vacuum hoses.
5. Remove vacuum hoses from intake manifold to brake booster, vacuum sensor, and A/C magnet switch VSV connector. Remove engine ground wire. Disconnect knock sensor and EGR VSV harness connectors. Remove engine harness clamps from brackets on intake manifold. Remove 2 intake manifold support braces. Remove 6 intake manifold mounting bolts and 2 mounting nuts.
6. Disconnect fuel injector harness connectors. Disconnect fuel return hose from fuel return pipe. Remove fuel inlet hose by removing pressure pulsation damper and washer gaskets.
7. Remove 2 fuel rail mounting bolts. Gently twist each injector to ease removal. Remove fuel rail with 4 injectors attached, using care not to drop injectors from rail. Replace injector if dropped. Remove 4 injector insulators and 2 rail spacers from intake manifold. Remove fuel injectors from fuel rail by gently pulling. Remove pressure regulator from fuel rail.

1. Install NEW grommets and "O" rings onto injectors. Apply light coat of gasoline to "O" rings and install injectors to fuel rail. (Scheme 2) Install 4 injector insulators and 2 rail spacers in position on cylinder head.
2. Place injectors with attached fuel rail into injector ports on cylinder head. Ensure injectors twist/rotate smoothly. (Scheme 2) If injectors do not rotate smoothly, check "O" rings for binding and for proper installation. Replace "O" ring(s) as required. Ensure injector electrical connectors are positioned upward and on cam cover side of fuel rail.
3. Install fuel rail bolts. Install fuel inlet pipe and pulsation damper. To complete installation, reverse removal procedure. Tighten all nuts and bolts to specification. See appropriate «TORQUE SPECIFICATIONS»(/toyota/camry/v30-1990-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__torque-specifications) table at end of article. Turn ignition on to pressurize fuel system and check for fuel leaks.

Scheme 2

1. Disconnect battery negative cable. Drain coolant. On A/T equipped models, disconnect throttle cable from throttle body and bracket. On all models, disconnect accelerator cable and bracket from throttle body.
2. Disconnect airflow meter connector. Disconnect vacuum hoses to air cleaner duct hose. Remove air cleaner cap, airflow meter and air cleaner duct hose as an assembly. Remove cover from top of engine and locate emission control valve set assembly.
3. Mark/label all vacuum hose positions for reassembly reference. Disconnect vacuum hoses to IACV VSV and to 2 other VSV's on control valve assembly. Disconnect VSV connectors and EGR temperature sensor harness connector clamp. Remove 2 bolts and remove emission control valve set assembly.
4. At IACV end of intake chamber, disconnect vacuum hoses for brake booster, power steering VSV and for cruise control. Disconnect 2 ground straps and wiring harness clamp. Disconnect cold start injector connector.
5. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/toyota/camry/v30-1990-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release) . At cold start injector, slowly loosen and remove union bolt and 2 washer gaskets from fuel pipe. Move cold start injector fuel pipe aside.
6. Remove engine removal hook and air intake chamber support brace. Remove EGR pipe by loosening 2 union fittings and removing 2 mounting bolts. Remove mounting bolt and disconnect hydraulic pressure pipe from air intake chamber. Mark/label and remove 3 emission control vacuum hoses at throttle body.
7. Remove coolant by-pass hoses from throttle body. Disconnect EGR temperature sensor connector. Disconnect wiring connectors to ISC valve and TPS. Disconnect ISC valve air hose and P/S vacuum hose. Remove air intake chamber mounting bolts and remove chamber.
8. Disconnect wiring connectors for coolant temperature sensor and 6 fuel injectors. Disconnect 3 wiring harness clamps from left fuel rail. Disconnect fuel return hoses from fuel pressure regulator and from No. 1 fuel pipe. Disconnect fuel inlet hose from fuel filter. To remove No. 2 fuel pipe, remove 2 union bolts, 4 gaskets and remove fuel pipe from end of each fuel rail.
9. Remove 2 left fuel rail mounting bolts and remove left fuel rail with 3 injectors attached. Remove bolts retaining air pipe and hoses. Remove 3 right fuel rail mounting bolts and remove right fuel rail with injectors attached. Remove 6 injectors and 4 spacers from fuel rails. Remove 6 insulators from intake manifold.

1. Apply light coat of gasoline to "O" rings and install 2 "O" rings and 2 NEW grommets to each injector. Install injectors into fuel rails. Install 6 insulators and 4 spacers to intake manifold.
2. Install each fuel rail with 3 injectors into insulators in intake manifold. Ensure injectors rotate smoothly and injector connectors are positioned upward toward cam cover. If injectors do not rotate smoothly, remove and recheck "O" rings for proper installation. Install 5 fuel rail mounting bolts and tighten to 115 INCH lbs. (13 N.m).
3. Install air pipe and air pipe hoses. Tighten air pipe retaining bolts to 74 INCH lbs. (8.3 N.m). Install No. 2 fuel pipe to end of fuel rails with 4 NEW gaskets and 2 union bolts. Tighten union bolts to 25 ft. lbs. (34 N.m).
4. Connect 3 wiring harness clamps to left fuel rail. Connect harness connectors for 6 injectors and coolant temperature sensor. Connect fuel inlet to filter and tighten to 22 ft. lbs. (29 N.m). Connect return hoses to fuel pipe.
5. Install air intake chamber to intake manifold and tighten bolts to 32 ft. lbs. (43 N.m). Connect ISC and P/S air hoses. Connect TPS and ISC harness connectors. Connect EGR temperature sensor connector, coolant hoses to throttle body and vacuum hoses to BVSV's. Connect hydraulic pressure pipe to intake chamber.
6. Install EGR pipe bolt and union fitting. Tighten EGR bolt to 13 ft. lbs. (18 N.m). Tighten pipe union fitting to 58 ft. lbs. (78 N.m). Install air intake chamber brace and engine removal hook. Tighten bolts to 29 ft lbs. (39 N.m).
7. Connect cold start injector fuel tube and harness connector. Tighten union bolt fitting to 11 ft. lbs. (15 N.m). Connect ground straps and wiring harness retaining clamp.
8. To complete installation, reverse removal procedure. Tighten all nuts and bolts to specification. See appropriate «TORQUE SPECIFICATIONS»(/toyota/camry/v30-1990-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__torque-specifications) table at end of article. Turn ignition on and check for fuel leaks.

OXYGEN (O2) & SUB-OXYGEN SENSORS

Note. To ease removal of O2 sensor and/or its mounting bolts from exhaust pipe/manifold, it may be necessary to apply penetrating oil to threads. Also to ease O2 sensor removal, run engine a few minutes to heat exhaust system to about 120°F (48°C).

Removal

1. Turn engine off. Disconnect O2 sensor electrical connector. Remove 2 mounting bolts/nuts and remove O2 sensor from manifold/pipe. Some O2 and sub-oxygen sensors screw into exhaust manifold or header pipe in front of converter.
2. When removing an O2 sensor that will be reused, protect its permanent pigtail from damage by using proper socket wrench (if required). After removal, ensure sensor tip is free of contaminants. Replace sensor as required. DO NOT use cleaning solvents on sensor tip.

Before installing O2 sensor, apply anti-seize compound or silicone to O2 sensor threads or to mounting bolt threads. Screw O2 sensor into exhaust, or install gasket and O2 sensor using mounting bolts.

FUEL PRESSURE REGULATORS

Note. If component removal and installation is primarily an unbolt and bolt-on procedure, only a torque specification may be furnished. See appropriate TORQUE SPECIFICATIONS table at end of article.

Removal & Installation (2.2L 5S-FE)

1. Disconnect battery negative cable. To remove pressure regulator from fuel rail, it is not necessary to remove intake manifold. Disconnect vacuum hose from pressure regulator. Release fuel pressure at fuel filter. See «FUEL SYSTEM PRESSURE RELEASE»(/toyota/camry/v30-1990-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release) .
2. Position cloth under pressure regulator fuel return pipe fitting. Remove union bolt using care not to lose 2 washer gaskets. Remove 2 mounting bolts, and remove pressure regulator from fuel rail.
3. To install pressure regulator, apply light coat of gasoline to NEW "O" ring and install onto pressure regulator. Carefully insert pressure regulator into fuel rail, and ensure pressure regulator and "O" ring are properly seated to rail. Install mounting bolts and tighten to 48 INCH lbs. (5.4 N.m).
4. Install fuel return pipe and union bolt with washer gaskets. Tighten union bolt to 14 ft. lbs. (19 N.m). Connect vacuum hose. Turn ignition on and check for leaks.

Removal & Installation (3.0L 3VZ-FE)

1. Remove 2 nuts retaining top engine cover and remove cover. Disconnect vacuum hose from pressure regulator. Release fuel pressure at fuel filter. See «FUEL SYSTEM PRESSURE RELEASE»(/toyota/camry/v30-1990-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release) . Loosen lock nut and unscrew pressure regulator from fuel rail.
2. To install, fully loosen lock nut on pressure regulator. Apply light coat of gasoline to NEW "O" ring and install onto recess of pressure regulator. Install pressure regulator completely into fuel rail.
3. Turn pressure regulator counterclockwise until vacuum pipe faces upward. Tighten lock nut to 16 ft. lbs. (22 N.m). Connect fuel hose and vacuum hose. Install engine cover.

1. Disconnect battery negative cable. Drain coolant. Disconnect throttle cable (A/T) and accelerator cable from throttle body linkage. Disconnect air temperature sensor connector and cruise control cable clamp from air cleaner housing.
2. Disconnect air cleaner hose from throttle body. Remove air cleaner cap, resonator and air cleaner hose as one assembly. Disconnect TPS and ISC valve connectors from throttle body. Before disconnecting emission control vacuum hoses, label hose-to-throttle body positions for reassembly purposes.
3. Remove vacuum hoses from throttle body. Remove 4 throttle body mounting bolts. Disconnect PCV valve hose, coolant by-pass hoses and air tube hose. Remove throttle body.
4. To install, reverse removal procedure. Tighten all nuts and bolts to specification. See appropriate «TORQUE SPECIFICATIONS»(/toyota/camry/v30-1990-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__torque-specifications) table at end of article.

1. Disconnect battery negative cable. Drain coolant. Disconnect throttle cable (A/T) and accelerator cable from throttle body linkage. Disconnect air cleaner duct hose clamp from throttle body.
2. Disconnect 2 air hoses from air cleaner duct hose. Remove air cleaner cap, airflow meter and air cleaner duct hose as an assembly. Unplug throttle position sensor connector. Disconnect PCV valve hose. Disconnect coolant by-pass hoses.
3. Mark/label and disconnect emission control vacuum hoses from throttle body. Disconnect throttle cable bracket (if necessary). Remove throttle body mounting bolts and remove throttle body.
4. To install, reverse removal procedure. Tighten all nuts and bolts to specification. See appropriate «TORQUE SPECIFICATIONS»(/toyota/camry/v30-1990-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__torque-specifications) table at end of article.

1. Disconnect battery negative cable. Disconnect cold start injector connector. (Scheme 3) Release fuel pressure at fuel filter. See «FUEL SYSTEM PRESSURE RELEASE»(/toyota/camry/v30-1990-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release). Position cloth under cold start injector fuel pipe and remove union bolt from cold start injector. Use care not to lose 2 washer gaskets.
2. Unbolt 2 nuts and remove cold start injector from IACV. Mark relationship positions of vacuum hoses connected to IACV. Remove all vacuum hoses from IACV. Remove 4 nuts retaining IACV to intake manifold, noting position of 2 ground straps. Remove IACV by carefully prying with a flat-bladed screwdriver between IACV and intake manifold.

1. To install IACV, install NEW gasket to intake surface. Apply NEW seal packing to IACV and apply light coat of engine oil to rubber portions. (Scheme 4) Install IACV to intake manifold and install 2 ground straps.
2. Install and tighten 4 IACV mounting nuts to 115 INCH lbs. (13 N.m). Install cold start injector using NEW gasket. Tighten nuts to 74 INCH lbs. (8.3 N.m).
3. Install fuel pipe union bolt using NEW washer gaskets (if available). Tighten union bolt to 11 ft. lbs. (15 N.m). Connect cold start injector connector. Turn ignition on and check for fuel leaks.

Scheme 3

Scheme 4

TORQUE SPECIFICATIONS

DISTRIBUTOR TORQUE SPECIFICATIONS

FUEL INJECTION TORQUE SPECIFICATIONS

FUEL INJECTION TORQUE SPECIFICATIONS

FUEL PUMP TORQUE SPECIFICATIONS

THROTTLE BODY TORQUE SPECIFICATIONS

See also:
• TORQUE SPECIFICATIONS
• FUEL SYSTEM PRESSURE RELEASE