Engine Controls - Remove/install/overhaul: Removal & Installation Toyota Corolla VIII

Removal & Installation

Ensure ignition is off. Remove ECM. See ECM LOCATION table. To install, reverse removal procedure.

ECM LOCATION

1. Ensure ignition is off. Disconnect electrical connector from ECT sensor. See «ENGINE COOLANT TEMPERATURE (ECT) SENSOR LOCATION»(ref-22347-S23695465202001010300000) table. To verify wire colors for proper sensor identification, see appropriate wiring diagram in «WIRING DIAGRAMS»(ref-22341) article. NOTE: The ECT sensor may be also identified using appropriate illustration in «THEORY/OPERATION - 1.6L»(ref-22340) article.
2. Drain cooling system. Remove ECT sensor and gasket. To install, reverse removal procedure using NEW gasket. Tighten ECT sensor to specification (if available). See «TORQUE SPECIFICATIONS»(ref-22347-S04237228942001010300000) . Fill cooling system.

ENGINE COOLANT TEMPERATURE (ECT) SENSOR LOCATION

Disconnect electrical connector at intake air temperature sensor. Intake air temperature sensor is located on top cover of air filter housing. Remove intake air temperature sensor from air filter housing. To install, reverse removal procedure.

Disconnect electrical connector and vacuum hose from MAP sensor. See MAP SENSOR LOCATION table. Remove bolt and MAP sensor. To install, reverse removal procedure.

Note. MAP sensor may also be identified using appropriate illustration in THEORY/OPERATION - 1.6L article. The MAP sensor has a vacuum hose connected to it and may be identified by wire colors. See appropriate wiring diagram in WIRING DIAGRAMS article.

MAP SENSOR LOCATION

For oxygen sensor servicing, procedure is just primarily an unbolt and bolt-on procedure. Disconnect electrical connector for oxygen sensor. Remove retaining nuts or unscrew oxygen sensor. Remove oxygen sensor and gasket (if equipped). To install, reverse removal procedure using NEW gasket (if equipped). Tighten oxygen sensor or retaining nuts to specification. See TORQUE SPECIFICATIONS .

Removal (A/T)

1. The PNP switch is located on side of transmission/transaxle. (Scheme 1) Remove necessary components for access to PNP switch.
2. Disconnect electrical connector from PNP switch. Disconnect shift cable or shift linkage from control lever (if equipped) on transmission/transaxle for access to PNP switch.
3. Remove nut, washer and control lever (if equipped) from transmission/transaxle. Bend tabs upward on lock plate, away from PNP switch retaining nut. Remove PNP switch retaining nut, lock plate, PNP switch retaining bolt(s) and PNP switch.

Installation

1. Using NEW lock plate, install PNP switch on transmission/transaxle. Install and tighten PNP switch retaining nut and PNP switch retaining bolt(s) to specification. See «TORQUE SPECIFICATIONS»(ref-22347-S04237228942001010300000). Bend over tab on lock plate against PNP switching retaining nut.
2. Reinstall control lever, washer and nut on PNP switch. Reconnect shift cable or shift linkage on control lever. Check that engine starts only with shift lever in Park and Neutral. If PNP switch adjustment is required, go to next step.
3. Ensure parking brake is applied. Place shift lever in Neutral. It may be necessary to remove control lever (if equipped) for access to PNP switch retaining bolt(s). Loosen PNP switch retaining bolt(s).
4. Rotate PNP switch so neutral base line aligns with the groove. (Scheme 2) Tighten PNP switch retaining bolt(s) to specification. See «TORQUE SPECIFICATIONS»(ref-22347-S04237228942001010300000).
5. Ensure continuity exists between specified terminals on PNP switch in relation to shift lever position. See «SYSTEM/COMPONENT TESTS - 1.6L»(ref-22342) article. Reinstall electrical connector.

Scheme 1

Scheme 2

The TP sensor is mounted on throttle body. Service information is not available from manufacturer at time of publication. For adjustment of TP sensor, see ADJUSTMENTS article.

Removal

1. Disconnect electrical connector from vehicle speed sensor. Vehicle speed sensor is mounted on firewall side of transaxle and contains a 3-pin electrical connector.
2. Remove retaining bolt and vehicle speed sensor with "O" ring from transaxle. If necessary to remove drive gear assembly from vehicle speed sensor, remove retaining clip from outside of vehicle speed sensor. Retaining clip is located just below the "O" ring groove on vehicle speed sensor. Remove drive gear from vehicle speed sensor.

To install, reverse removal procedure using NEW "O" ring. Coat "O" ring with ATF before installing on vehicle speed sensor. Tighten retaining bolt to specification. See TORQUE SPECIFICATIONS .

Disconnect electrical connector at distributor. Disconnect spark plug wires from distributor cap. Remove distributor hold-down bolt and distributor. Remove "O" ring from distributor housing.

1. Remove distributor cap and rotor from distributor. Remove ignition coil dust cover and gasket. Remove nuts and disconnect wires from ignition coil, mounted on side of distributor housing. Remove screws and ignition coil from distributor housing.
2. Remove wiring clamp from side of distributor housing. Remove screw and condenser from side of distributor housing. To check pick-up coil, see PICK-UP COIL RESISTANCE and PICK-UP COIL AIR GAP under IGNITION CHECKS (DISTRIBUTOR TYPE IGNITION SYSTEM) in «BASIC TESTING»(ref-22339) article. Pick-up coil and distributor must be replaced as an assembly if defective.
3. To check ignition coil resistance, see IGNITION COIL RESISTANCE under IGNITION CHECKS (DISTRIBUTOR TYPE IGNITION SYSTEM) in «BASIC TESTING»(ref-22339) article. Replace ignition coil if resistance is not within specification.
4. To reassemble, reverse disassembly procedure. Apply seal packing at ignition coil-to-distributor housing surface before installing ignition coil on distributor housing.
5. Ensure wires to ignition coil are properly engaged in grooves on side of ignition coil and wires do not contact the pick-up coil assembly. Use NEW gasket when installing ignition coil dust cover.

1. Rotate crankshaft pulley clockwise until groove on crankshaft pulley aligns with "0" mark on timing belt cover to position cylinder No. 1 (front cylinder at timing belt end of engine) at TDC on compression stroke. Ensure slot in camshaft is properly positioned. (Scheme 3)
2. Install NEW "O" ring on distributor housing. Coat "O" ring with engine oil. Align cutout on drive coupling with groove on distributor housing. (Scheme 3)
3. Install distributor so distributor mounting flange bolt hole aligns with bolt hole on cylinder head. Install and tighten distributor hold-down bolt to specification. See «TORQUE SPECIFICATIONS»(ref-22347-S04237228942001010300000).
4. To install remaining components, reverse removal procedure. Check ignition timing. See «ADJUSTMENTS»(ref-22348) article.

Scheme 3

CRANKSHAFT POSITION SENSOR R & I

Note. To test crankshaft position sensor resistance, see CRANKSHAFT POSITION SENSOR under IGNITION CHECKS (DISTRIBUTOR TYPE IGNITION SYSTEM) or IGNITION CHECKS (DISTRIBUTORLESS IGNITION SYSTEM) in BASIC TESTING article.

1. Crankshaft position sensor is located just above crankshaft pulley. (Scheme 4) Disconnect electrical connector for crankshaft position sensor. Remove bolt and crankshaft position sensor.
2. To install, reverse removal procedure. Tighten bolt to specification. See «TORQUE SPECIFICATIONS»(ref-22347-S04237228942001010300000).

Scheme 4

Ignition coil is mounted on the side of distributor, inside the distributor cap. Manufacturer lists servicing procedure with distributor removed from the engine. For servicing of ignition coil, see DISTRIBUTOR under IGNITION SYSTEM.

1. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-22347-S08036908212001010300000) under FUEL SYSTEM. Remove fuel tank filler cap to release any fuel pressure from fuel tank.
2. Remove rear seat and cover plate on floor panel for access to fuel pump. Disconnect electrical connector at fuel pump. Using Flare Nut Wrench (SST 09631-22020), disconnect fuel outlet line from fuel pump mounting bracket. Disconnect fuel return hose from fuel pump mounting bracket.
3. Remove fuel pump mounting bracket-to-fuel tank bolts. Remove fuel pump assembly and gasket from fuel tank. Use care not to damage fuel filter on bottom of fuel pump and fuel gauge sending unit when removing fuel pump.

1. To install, reverse removal procedure using NEW gasket. Tighten fuel pump mounting bracket-to-fuel tank bolts and fuel outlet line to specification. See «TORQUE SPECIFICATIONS»(ref-22347-S04237228942001010300000) .
2. Operate fuel pump and check for fuel leaks. See FUEL PUMP OPERATION under FUEL SYSTEM in «BASIC TESTING»(ref-22339) article.

Scheme 5

1. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-22347-S08036908212001010300000) under FUEL SYSTEM. Disconnect vacuum hose and fuel return hose from fuel pressure regulator. Fuel pressure regulator is located on end of fuel rail.
2. Remove bolts and fuel pressure regulator with "O" ring from fuel rail. Remove "O" ring from fuel pressure regulator.

1. To install, reverse removal procedure using NEW "O" ring. Coat "O" ring with gasoline before installing fuel pressure regulator on fuel rail.
2. Ensure fuel pressure regulator rotates smoothly in fuel rail after installation to verify proper seating of "O" ring and fuel pressure regulator fits flat against the fuel rail. If fuel pressure regulator does not rotate smoothly, check for improper "O" ring installation.
3. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-22347-S04237228942001010300000) . Operate fuel pump and check for fuel leaks. See FUEL PUMP OPERATION under FUEL SYSTEM in «BASIC TESTING»(ref-22339) article.

1. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-22347-S08036908212001010300000) under FUEL SYSTEM. Remove air cleaner cap assembly. (Scheme 6)
2. Disconnect necessary electrical connectors, air hoses and vacuum hoses for removal of air intake chamber with throttle body. Disconnect PCV hose from valve cover. Remove bolts/nuts, air intake chamber and gasket.
3. Note location of electrical connectors on fuel injectors for reassembly reference. Disconnect electrical connectors from fuel injectors. Remove union bolt and disconnect fuel inlet hose from fuel rail. Disconnect vacuum hose and fuel return hose from fuel pressure regulator. CAUTION: When removing fuel rail, use care not to allow fuel injectors to fall from fuel rail.
4. Remove fuel rail-to-intake manifold bolts. Remove fuel rail with fuel injectors. Remove spacers and insulators from intake manifold. Remove fuel injectors from fuel rail. Remove "O" ring and grommet from fuel injector.

1. To install, reverse removal procedure using NEW grommets, "O" rings, insulators and gaskets. Coat "O" ring with gasoline before installing "O" ring on fuel injector. Use twisting motion when installing fuel injector on fuel rail. Ensure insulators and spacers are installed on intake manifold.
2. When installing fuel rail, install fuel rail with fuel injectors on intake manifold. Loosely install fuel rail-to-intake manifold bolts.
3. Ensure fuel injectors rotate smoothly. If fuel injectors do not rotate smoothly, check for improper "O" ring installation. Ensure electrical connector on each fuel injector is facing upward.
4. Tighten fuel rail-to-intake manifold bolts to specification. See «TORQUE SPECIFICATIONS»(ref-22347-S04237228942001010300000). To install remaining components, reverse removal procedure. Tighten air intake chamber bolts/nuts to specification in sequence. (Scheme 7)
5. Operate fuel pump and check for fuel leaks. See FUEL PUMP OPERATION under FUEL SYSTEM in «BASIC TESTING»(ref-22339) article.

Scheme 6

Scheme 7

1. Drain cooling system. Disconnect necessary electrical connectors and hoses for removal of air cleaner upper cap assembly. Disconnect air cleaner hose at throttle body. Remove air cleaner upper cap assembly and air cleaner hose.
2. Disconnect control cables, control cable brackets, electrical connectors and vacuum hoses at throttle body. Remove bolts/nuts, throttle body and gasket from air intake chamber.
3. Disconnect remaining coolant hoses and air hose from bottom of throttle body. Remove throttle body. Remove screws, Idle Air Control (IAC) valve and gasket from throttle body (if necessary).

1. To install, reverse removal procedure using NEW gaskets. Ensure gasket for throttle body is installed with protrusion facing downward. (Scheme 8)
2. Tighten bolts/nuts to specification. See «TORQUE SPECIFICATIONS»(ref-22347-S04237228942001010300000). Fill cooling system.

Scheme 8

IAC valve is located on throttle body. See THROTTLE BODY under FUEL SYSTEM for servicing of IAC valve.

For EGR VSV servicing, procedure is just primarily an unbolt and bolt-on procedure. See EGR VSV LOCATIONS table. The EGR VSV may be identified using appropriate illustration in SYSTEM/COMPONENT TESTS - 1.6L article.

EGR VSV LOCATIONS

For EGR valve servicing, procedure is just primarily an unbolt and bolt-on procedure using a NEW gasket. Tighten bolts/nuts to specification. See TORQUE SPECIFICATIONS .

For PCV valve servicing, procedure is just primarily a removal and installation procedure.