Engine Controls - Remove/install/overhaul Toyota Tercel L40

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

1. Disconnect battery negative cable. Disconnect wires from spark plugs. Disconnect distributor electrical connector.
2. Set cylinder No. 1 to TDC of compression stroke. Remove distributor hold-down bolt and 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. Coat NEW "O" ring with oil and install onto distributor housing. Ensure cylinder No. 1 is at TDC by viewing camshaft slot. Slot should be vertical with a small, round indentation on right side of slot. Timing marks should be at TDC.
2. Align protrusion on lower distributor housing with groove in wing of drive coupling. (Scheme 1) Insert distributor with flange mark aligned with nut on top of valve cover. (Scheme 2)
3. Connect spark plug wires. Connect distributor electrical connector. Connect battery negative cable. Set ignition timing. Tighten distributor hold-down bolt to 13 ft. lbs. (18 N.m).

Scheme 1

Scheme 2

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. Remove rear seat cushion. Disconnect fuel pump and fuel sender electrical connector. Remove fuel pump access cover. Release fuel pressure at filter. See 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 from tank.
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.
5. To install, reverse removal procedure. Use NEW retaining clip to install filter. Use NEW gasket between fuel pump bracket and tank. Tighten fuel pump bracket-to-tank nuts to 26 INCH lbs. (2.9 N.m). Turn ignition on and check for fuel leaks.

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. Remove PCV hoses. Remove air cleaner cap and hose. Disconnect accelerator cable. Disconnect throttle cable (A/T). Disconnect vacuum sensing hose from fuel pressure regulator.
2. Release fuel pressure at filter. See FUEL SYSTEM PRESSURE RELEASE. Disconnect fuel return hose from fuel return pipe. Disconnect fuel return pipe from fuel pressure regulator.
3. Disconnect fuel inlet pipe from fuel rail. Disconnect injector connectors. Remove fuel rail with injectors attached. Remove 2 spacers and 4 injector insulators from cylinder head.

1. Apply light coat of gasoline to NEW "O" rings and install "O" rings and NEW grommets onto injectors. Install injectors into fuel rail in the following order. Starting at pressure regulator end of fuel rail install Dark Blue injector, Brown injector, Dark Blue injector, and Brown injector (into last hole in fuel rail).
2. When installing injectors into fuel rail, turn each injector from left to right while pushing downward to fully seat injector into fuel rail. Install 4 insulators and 2 spacers to cylinder head.
3. Install fuel rail (with 4 injectors attached) to cylinder head. Ensure injectors rotate smoothly. If injectors do not rotate smoothly, check "O" rings for proper installation. Position injector connectors upward on camshaft cover side. Install 2 fuel rail bolts, and tighten to 14 ft. lbs. (19 N.m).
4. Connect 2 Gray wiring harness injector connectors to Dark Blue injectors. Connect 2 Brown wiring harness connectors to Brown injectors. Connect fuel inlet pipe using NEW washer gaskets and tighten union bolt to 22 ft. lbs. (29 N.m). Connect fuel return pipe to pressure regulator and tighten to 14 ft. lbs. (19 N.m).
5. To complete installation, reverse removal procedure. Tighten all nuts and bolts to specification. See appropriate TORQUE SPECIFICATIONS table at end of article.

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).

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. Installation 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.

1. Disconnect vacuum hose from pressure regulator. Release fuel pressure at fuel filter. See FUEL SYSTEM PRESSURE RELEASE. Remove fuel pipe union bolt at pressure regulator. Remove pressure regulator mounting bolts from fuel rail.
2. To install, apply light coat of gasoline to "O" ring and install onto pressure regulator. Install pressure regulator to fuel rail. Ensure regulator rotates/twists smoothly to verify "O" ring is positioned properly. If injector does not rotate, remove and replace "O" ring.
3. Tighten 2 mounting bolts to 69 INCH lbs. (7.8 N.m). Install and tighten fuel pipe union bolt to pressure regulator to 14 ft. lbs. (19 N.m). Connect vacuum hose. Turn ignition on and check for fuel leaks.

1. Disconnect battery negative cable. Drain coolant. Disconnect accelerator and throttle cables (A/T) from throttle body linkage. Unplug throttle position sensor connector.
2. Mark/label and disconnect emission control and PCV vacuum hoses from throttle body. Remove fuel rail with attached injectors. See FUEL INJECTORS & FUEL RAILS.
3. Remove 2 bolts and 2 nuts retaining throttle body. Remove throttle body enough to disconnect 2 coolant hoses and 2 air hoses. Remove throttle body.
4. To install, reverse removal procedure. See FUEL INJECTORS & FUEL RAILS. Tighten throttle body mounting nuts and bolts to 115 INCH lbs. (13 N.m).

TORQUE SPECIFICATIONS

DISTRIBUTOR TORQUE SPECIFICATIONS

FUEL INJECTION TORQUE SPECIFICATIONS (1)

FUEL PUMP TORQUE SPECIFICATIONS

THROTTLE BODY TORQUE SPECIFICATIONS