Engine Controls - Remove/install/overhaul Toyota Celica T180

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 this section.

Removal

1. Disconnect negative battery cable. On 2.0L Turbo, remove intercooler. To remove intercooler, see «TURBOCHARGER»(/toyota/celica/t180-1989-1993/remont/removal-installation/#engine-controls-removeinstalloverhaul) under AIR INDUCTION SYSTEM.
2. On all engines, disconnect spark plug wires from distributor cap. Disconnect distributor wiring connector. Remove distributor hold-down bolt(s). Remove distributor. Remove "O" ring from distributor housing and discard.

Installation

1. Set No. 1 cylinder to TDC of compression stroke. Install new "O" ring on distributor housing. Coat "O" ring with oil. Align mark of coupling with groove on housing. (Scheme 1)
2. Insert distributor, aligning center of distributor flange with bolt hole on cylinder head. Connect distributor wiring connector. Install spark plug wires. Set ignition timing.
3. To complete installation, reverse removal procedure. Connect negative battery cable. Set ignition timing. Tighten distributor hold-down bolt(s). See «TORQUE SPECIFICATIONS»(/toyota/celica/t180-1989-1993/remont/removal-installation/#engine-controls-removeinstalloverhaul).

Scheme 1

FUEL SYSTEM PRESSURE RELEASE

Disconnect negative battery terminal. Place container under fitting to be loosened. Use a rag to cover fuel line/component. Slowly loosen fitting, allowing pressurized fuel to spill into container. After fuel system pressure is released, disconnect and plug fitting.

Removal & Installation (2.0L)

1. Disconnect negative battery cable. Disconnect fuel pump and fuel sender electrical connectors at floor service hole cover, located in luggage compartment.
2. Remove service hole cover. Remove screws attaching fuel sender gauge. Remove fuel sender gauge. Drain fuel from fuel tank. Install new gasket to fuel sender gauge. Reinstall fuel sender gauge.
3. Remove left rear wheel. Remove fuel tank protector. Remove fuel tank filler pipe protector. Disconnect filler pipe from fuel tank. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/toyota/celica/t180-1989-1993/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release) .
4. Remove fuel filler cap. Disconnect fuel outlet hose, return hose and fuel evaporation hose. Remove fuel tank. Remove screws securing fuel pump and bracket assembly to fuel tank. Remove fuel pump and bracket assembly.
5. Pull lower end of fuel pump (with filter) from bracket. Remove 2 nuts securing fuel pump wires to fuel pump and disconnect wires. Disconnect fuel hose from pump. Remove fuel pump. To install, reverse removal procedure.

Removal & Installation (1.6L & 2.2L)

1. Disconnect negative battery cable. Remove gas cap. Remove rear seat cushion. Disconnect fuel pump and fuel sender electrical connector. Remove fuel pump access cover. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/toyota/celica/t180-1989-1993/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release) .
2. Disconnect fuel lines from fuel pump bracket assembly. Remove bolts securing fuel pump and bracket assembly to fuel tank. Remove fuel pump and bracket assembly.
3. Remove nuts and washers retaining fuel sending unit wires. Disconnect wires. Remove screws retaining sending unit and separate sending unit from fuel pump and bracket assembly.
4. Pull lower end of fuel pump (with filter) from bracket. Remove 2 nuts securing fuel pump wires to fuel pump. Disconnect wires. Disconnect fuel hose from fuel pump. Remove fuel pump. To install, reverse removal procedure.

FUEL INJECTORS & FUEL RAILS

Note. Always install new grommets and "O" rings when removing or replacing fuel injectors. Ensure injectors rotate smoothly in injector ports and fuel rail. If injectors DO NOT rotate smoothly, check "O" rings for proper installation.

Removal (1.6L)

1. Disconnect negative battery cable. Disconnect vacuum sensing hose from fuel pressure regulator. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/toyota/celica/t180-1989-1993/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release) .
2. Disconnect fuel return hose from fuel pressure regulator. Remove union bolt, 2 gaskets and disconnect fuel inlet hose from fuel rail.
3. Disconnect fuel injector connectors. Remove 2 bolts and fuel rail with 4 injectors. Remove 4 insulators and 2 spacers from cylinder head. Pull out injectors from fuel rail. Remove "O" ring and grommet from each fuel injector.

1. Install new grommet to each fuel injector. Apply a light coat of gasoline to new "O" ring and install on injector. Install fuel injectors to fuel rail while turning fuel injector from left to right.
2. Place 4 new insulators and 2 new spacers in position on cylinder head. Place 4 injectors with fuel rail and position on cylinder head. Ensure fuel injectors rotate smoothly.
3. Position fuel injector connector upward. Install fuel rail mounting bolts and tighten. See «TORQUE SPECIFICATIONS»(/toyota/celica/t180-1989-1993/remont/removal-installation/#engine-controls-removeinstalloverhaul) . Connect fuel inlet hose to fuel rail.
4. Connect fuel injector connectors. Connect fuel return hose to fuel pressure regulator. Connect negative battery cable. Check for fuel leaks.

Removal (2.0L)

1. Disconnect negative battery cable. Drain coolant from engine and intercooler. Disconnect accelerator cable from throttle linkage. Remove intercooler. To remove intercooler, see «TURBOCHARGER»(/toyota/celica/t180-1989-1993/remont/removal-installation/#engine-controls-removeinstalloverhaul) under AIR INDUCTION SYSTEM.
2. Remove 4 bolts and air connector. Remove air connector bracket. Disconnect throttle position sensor connector. Disconnect idle speed control connector. Remove coolant hoses, air hose and vacuum hoses from throttle body. Remove 4 bolts and throttle body.
3. Disconnect fuel pressure regulator vacuum hose. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/toyota/celica/t180-1989-1993/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release) . Disconnect fuel return hose. Loosen lock nut and remove fuel pressure regulator. Remove EGR vacuum modulator. Disconnect injector connectors.
4. Disconnect fuel inlet hose from fuel rail. Remove 3 bolts and fuel rail with 4 fuel injectors. Remove 4 insulators and 3 spacers from intake manifold. Remove fuel injectors from fuel rail.

1. Install new grommets and "O" rings on injectors. Install 4 injectors on fuel rails. Install 4 insulators and 3 spacers on intake manifold.
2. Install 4 injectors with fuel rail into intake manifold. Ensure injectors rotate smoothly. If injectors do not rotate smoothly, check "O" rings for proper installation. Position injector connectors upward. Install 3 fuel rail bolts.
3. Connect fuel return hose to return pipe. Connect injector connectors. Install EGR modulator. Install fuel pressure regulator and throttle body. To complete installation, reverse removal procedure. Tighten all nuts and bolts. See «TORQUE SPECIFICATIONS»(/toyota/celica/t180-1989-1993/remont/removal-installation/#engine-controls-removeinstalloverhaul) . Check for fuel leaks.

Removal (2.2L)

1. Disconnect negative battery cable. Drain engine coolant. Disconnect throttle cable from throttle linkage (A/T). Disconnect accelerator cable from throttle linkage.
2. Remove air cleaner cap and air cleaner hose. Disconnect throttle position sensor connector. Disconnect water, air and vacuum hoses from throttle body as required. Remove throttle body.
3. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/toyota/celica/t180-1989-1993/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release) . Remove 2 union bolts, 4 gaskets and cold start injector pipe. Remove fuel pressure regulator. Remove bolt and right accelerator bracket. Disconnect engine wire clip from left accelerator bracket. Remove 2 bolts and left accelerator bracket.
4. Disconnect fuel injector connectors. Disconnect 2 wire clamps from timing belt cover. Disconnect 2 wire clamps from wire brackets on intake manifold.
5. Disconnect fuel hose from fuel return pipe. Loosen pulsation dampener. Loosen 2 bolts holding fuel rail to cylinder head. Remove pulsation dampener. Disconnect fuel inlet hose from fuel rail. Remove 2 bolts and fuel rail with 4 injectors.
6. Remove 4 insulators and 2 spacers from cylinder head. Pull out 4 injectors and 2 spacers from fuel rail. Remove "O" ring and grommet from each injector.

1. Install new grommet to injectors. Apply a light coat of gasoline to new "O" ring and install to injector. Install injectors to fuel rail by turning injector from left to right.
2. Install 4 new insulators and 2 spacers in position on cylinder head. Place 4 injectors together with fuel rail in position on cylinder head. Temporarily install 2 bolts holding fuel rail to cylinder head. Check that injectors rotate smoothly. Position injector connectors upward.
3. Connect fuel inlet pipe to fuel rail with 2 new gaskets and pulsation dampener. To complete installation, reverse removal procedure. Tighten all nuts and bolts to specification. See «TORQUE SPECIFICATIONS»(/toyota/celica/t180-1989-1993/remont/removal-installation/#engine-controls-removeinstalloverhaul) . Check for fuel leaks.

Disconnect sensor electrical connector. Remove 2 mounting nuts or bolts. Remove sensor. Some sub-oxygen sensors screw into exhaust manifold or header pipe.

Note. When removing sensor, protect its permanent pigtail from damage. Ensure sensor is free of contaminants. Avoid using cleaning solvents of any type.

Install sensor. Install nuts or bolts. Connect electrical connector. Oxygen sensor torque specification is not available from manufacturer.

1. Disconnect negative battery cable. Drain coolant. Disconnect throttle cable (A/T) and accelerator cable from throttle linkage. Disconnect air cleaner cap and air cleaner hose.
2. Unplug throttle position sensor. Disconnect idle speed control connector (2.2L). Disconnect PCV valve hose. Disconnect coolant by-pass hoses. Label and disconnect emission control vacuum hoses. Disconnect throttle cable bracket. Remove mounting bolts and throttle body.
3. To install, reverse removal procedure. Tighten all nuts and bolts. See «TORQUE SPECIFICATIONS»(/toyota/celica/t180-1989-1993/remont/removal-installation/#engine-controls-removeinstalloverhaul) .

1. Disconnect negative battery cable. Drain coolant. Remove intercooler. Disconnect accelerator cable from throttle linkage. Remove air connector and air connector bracket.
2. Unplug throttle position sensor and idle speed control valve connectors. Disconnect coolant by-pass hose and air hose. Label and disconnect emission control vacuum hoses. Remove throttle body.
3. To install, reverse removal procedure. Tighten all nuts and bolts. See «TORQUE SPECIFICATIONS»(/toyota/celica/t180-1989-1993/remont/removal-installation/#engine-controls-removeinstalloverhaul) .

1. Disconnect negative battery cable. Drain coolant. Remove air cleaner. Remove lower engine covers and suspension lower crossmember for access to catalytic converter. Remove front engine mount and bracket.
2. Remove alternator. Remove idler pulley bracket and A/C compressor (without disconnecting lines). Remove front exhaust pipe and catalytic converter. Without disconnecting lines, remove clutch cylinder.
3. Remove intercooler cool air inlet and intercooler protector. Remove intercooler and air connector.
4. Remove turbocharger heat insulator and oxygen sensor. Remove turbine outlet insulators. Remove turbocharger-to-block bracket. Remove oil pipe union bolt and oil pipe. Remove turbocharger. Remove turbine outlet elbow.

Note. Check for oil sludge in oil pipes. Replace if necessary.

Scheme 2

Inspection

1. Ensure turbine wheel turns smoothly. If impeller wheel will not turn or drags when turned, replace turbocharger assembly.
2. Place dial indicator on shaft end. Axial (forward-and-backward) shaft play should be.0051" (.13 mm) or less. If not, replace turbocharger.
3. Insert dial indicator into oil outlet hole through hole in spacer bearing. Set dial indicator against center of turbine shaft. Radial (up-and-down) play should be.0071" (.18 mm) or less. If not, replace turbocharger.

To install, reverse removal procedure. Use new gaskets and "O" rings. After installing turbocharger, pour 1 fluid ounce (30 cc) of new oil into oil inlet. Turn impeller wheel by hand to circulate oil onto bearings. Fill cooling system coolant.

1.6L & 2.2L

TORQUE SPECIFICATIONS (1.6L & 2.2L)

2.0L

TORQUE SPECIFICATIONS (2.0L)

See also:
• TURBOCHARGER
• FUEL SYSTEM PRESSURE RELEASE