Integrated ignition unit (contactless ignition system) [Toyota Corona T190]

Removal

1. Remove the cable from the negative terminal of the battery.

2. Disconnect the high-voltage wires from the distributor cap.

• a) Use a screwdriver to pull back the spring latch, lift the retaining clip up and detach the holder from the distributor cap;

• b) Disconnect the high-voltage wires from the rubber bushings;

Note: Do not pull on the wires under any circumstances, this may cause internal breaks in the wires.

3. Disconnect the connectors from the integrated ignition unit (contactless ignition system unit) or from the distributor.

4. Remove the contactless ignition system unit (distributor), by unscrewing the two bolts securing the block.



Then remove the O-ring seal from the distributor housing.

Disassembly

1. Remove the distributor cap and gasket by unscrewing the 3 bolts.

2. Remove the ignition distributor rotor.

3. Remove the ignition coil dust deflector together with the gasket.

4. Remove the ignition coil.

• a) Disconnect three or four (depending on the design) wires from the ignition coil terminals by unscrewing 2 nuts.

• b) (3S-F£, 4S-FE) Remove the wiring connector from the distributor cap.

• c) Unscrew 4 screws and remove the ignition coil.

• 5. (3S-FE, 4S-FE) Loosen the mounting screw and remove the capacitor.

7A-FE and 4A-FE (serial version)



8. Remove the switch by first unscrewing 3 screws and disconnecting 3 wires from the switch terminals; then, after unscrewing the 2 mounting screws, remove the switch.



7. Remove the wire holder and distributor wiring (combined ignition unit wiring harness):

• a) Disconnect the two connectors from the wire holder;
• b) Loosen the screw and remove the wire holder;

• c) Disconnect the distributor wire from the distributor housing.

6. Disconnect the capacitor by loosening the mounting bolt.

Checking the distributor

Turn the distributor shaft by hand and make sure that the shaft rotates smoothly, without gaps or jamming.

If there is a feeling of wear or sticking, replace the distributor housing.

Assembly

1. Install the capacitor.

7A-FE and 4A-FE (serial version)

2. Install the distributor wire and wire holder.

3. Install the switch by securing it with two screws and connecting three wires: black, blue and yellow to the switch terminals.



All engines



4. Install the ignition coil in the correct order.

• a) Remove old sealant.
• b) Apply fresh sealant to the contact surface of the ignition coil housing that mates with the surface of the ignition unit housing, as shown in the figure.

[The text is taken from the specified website www.ToyotaMan.ru]

• c) Install and secure the ignition coil with 4 screws.

5. Connect the wires to the ignition coil terminals, securing them with two nuts as shown in the figure.

Note: In some versions of the engines, three wires must be connected: black and two brown.

Note: When connecting the wires to the ignition coil, place the wires in the grooves provided on the side of the ignition coil.

Note: Make sure that the wires do not touch the angular pulse sensor rotor or the ignition module housing.

6. Install the ignition coil dust deflector, first installing a new gasket under the cover of the combined ignition unit housing.

7. Install the distributor rotor.

8. Install the distributor cap, securing it with 3 bolts.

Installation

1. Bring the piston of the 1st cylinder to TDC. Turning the engine shaft clockwise, align the mark "0" on the crankshaft pulley with the reference mark. The slot in the end of the camshaft should be positioned as shown in the figure.

4A-FE, 7A-FE

3S-FE, 4S-FE

2. Install the integrated ignition unit (contactless ignition system unit) or distributor, observing the sequence.

• a) Apply a layer of engine oil to the new O-ring seal on the housing.

• b) Align the protrusion on the ignition unit housing (contactless ignition system) or a distributor with a groove on the connecting sleeve.

• c) Insert the ignition unit (distributor), by centering its mounting flange with the mounting hole in the cylinder head and aligning the holes in the ignition unit flange with the holes for the mounting bolts in the cylinder head.
• d) Loosely tighten the two ignition unit mounting clamp bolts (distributor).

3. Connect the high-voltage wires to the distributor cap in accordance with the engine firing order: 1-3-4-2.



4. Connect the connectors of the combined ignition unit (contactless ignition system unit).

5. Adjust the ignition timing (see section "Adjusting the ignition timing angle" in chapter "Maintenance and general check and adjustment procedures").

6. After adjusting the ignition timing angle, finally secure the housing of the combined ignition unit to the cylinder head by tightening the mounting bolts. Tightening torque: 20 Nm.