1. IGNITION SYSTEM
IG-1

2. 3. As some tachometers are not compatible with this
ignition system, we recommend that you confirm
the compatibility of your unit before use.
4. Never allow the tachometer terminals to touch
ground as it could result in damage to the igniter
and/or ignition coil.
5. Do not disconnect the battery while the engine is
running.
6. Check that the igniter is properly grounded to the
body.
PRECAUTION
1. Do not leave the ignition switch on for more than 10
minutes if the engine does not start.
2. With a tachometer connected to the system, con-
nect the tester probe of the tachometer to terminal
IG(-) of the data link connector 1.
-IGNITION SYSTEM PRECAUTION
IG-2

3. ELECTRONIC SPARK ADVANCE (ESA)
The engine control module (ECM) is programmed with data for optimum ignition timing under all
operating conditions. Using data provided by sensors which monitor various engine functions
(rpm, intake air volume, engine coolant temperature, etc.), the ECM triggers the spark at precisely
the right instant.
SYSTEM CIRCUIT
-IGNITION SYSTEM SYSTEM CIRCUIT
IG-3

4. PREPARATION
SST (SPECIAL SERVICE TOOLS)
SSM (SPECIAL SERVICE MATERIALS)
RECOMMENDED TOOLS
09082-00050 TOYOTA Electrical Tester Set
08826-00080 Seal packing or equivalent
09843-18020 Diagnosis Check Wire
09200-00010 Engine Adjust Kit
EQUIPMENT
Spark plug cleaner
Timing light
Tachometer
Ignition coil
-IGNITION SYSTEM PREPARATION
IG-4

5. ON-VEHICLE INSPECTION
SPARK TEST
CHECK THAT SPARK OCCURS
(a) Disconnect the high-tension cords from the spark
plugs.
(b) Remove the spark plugs.
(c) Install the spark plugs to each high-tension cord.
(d) Ground the spark plug.
(e) Check if spark occurs while engine is being cranked.
HINT: To prevent gasoline from being injected from
injectors during this test, crank the engine for no more
than 1 - 2 seconds at a time.
If the spark does not occur, perform the test as fol-
lows:
CHECK POWER SUPPLY TO IGNITION COIL
AND IGNITER
1. Turn ignition switch to ON.
2. Check that there is battery voltage at ignition coil
positive (+) terminal.
CHECK RESISTANCE OF IGNITION COIL
(See page IG-8 )
Resistance: (Cold) (Hot)
Primary 0.36 - 0.55W 0.45 - 0.65W
Secondary 9.0 -15.4 kW 11.4 - 18.1 kW
CHECK RESISTANCE OF SIGNAL GENERATOR
(PICKUP COIL) (See page IG-8 )
Resistance: (Cold) (Hot)
NE(+) and NE(-) 370 - 550 W 475 - 650 W
CHECK RESISTANCE OF HIGH-TENSION CORD
(See page IG-6 )
Maximum resistance: 25 kW per cord
CHECK AIR GAP OF DISTRIBUTOR
(See page IG-8 )
Air gap: 0.2 - 0.4 mm (0.008 - 0.016 in.)
Check wiring between ECM, distributor and
igniter, and then try another ECM.
Check wiring between ignition switch to ignition
coil and igniter.
CHECK CONNECTION OF IGNITION COIL,
IGNITER AND DISTRIBUTOR CONNECTOR
CHECK IGT SIGNAL FROM ECM
(See page EG-149 )
Replace the distributor housing assembly.
Replace the distributor housing
assembly.
Replace the ignition coil.
TRY ANOTHER IGNITER
Replace the cord(s).
Connect securely.
SPARK TEST
BAD
BAD
BAD
BAD
BAD
BAD
BAD
-IGNITION SYSTEM ON-VEHICLE INSPECTION
IG-5

6. HIGH-TENSION CORDS INSPECTION
1. DISCONNECT HIGH-TENSION CORDS FROM
SPARK PLUGS
Disconnect the high - tension cords at the rubber
boot. Do not pull on the high-tension cords.
NOTICE: Pulling on or bending the cords may damage the
conductor inside.
2. REMOVE DISTRIBUTOR CAP WITHOUT
DISCONNECTING HIGH-TENSION CORDS
3. INSPECT HIGH-TENSION CORD RESISTANCE
Using an ohmmeter, measure the resistance without
disconnecting the distributor cap.
Maximum resistance:
25 kW per cord
If the resistance is greater than maximum, check the
terminals. If necessary, replace the high-tension cord
and/or distributor cap.
4. REINSTALL DISTRIBUTOR CAP
5. RECONNECT HIGH-TENSION CORDS TO SPARK
PLUGS
-IGNITION SYSTEM ON-VEHICLE INSPECTION
IG-6

7. 1. DISCONNECT HIGH-TENSION CORDS FROM
SPARK PLUGS
Disconnect the high-tension cords at the rubber
boot. Do not pull on the high-tension cords.
NOTICE: Pulling on or bending the cords may damage the
conductor inside.
2. REMOVE SPARK PLUGS
4. VISUALLY INSPECT SPARK PLUGS
Check the spark plug for electrode wear, thread
damage and insulator damage.
If abnormal, replace the spark plug.
Recommended spark plug:
W16EXR-U1 1 for ND
BPR5EY11 for NGK
5. ADJUST ELECTRODE GAP
Carefully bend the outer electrode to obtain the cor-
rect electrode gap.
Correct electrode gap:
1.1 mm (0.043 in.)
6. INSTALL SPARK PLUGS
Torque: 18 N-m (180 kgf-cm, 13 ft-lbf)
7. RECONNECT HIGH-TENSION CORDS TO SPARK
PLUGS
3. CLEAN SPARK PLUGS
Using a spark plug cleaner or wire brush, clean the
spark plug.
SPARK PLUGS INSPECTION
-IGNITION SYSTEM ON-VEHICLE INSPECTION
IG-7

8. 2. INSPECT SIGNAL GENERATOR (PICKUP COIL)
RESISTANCE
Using an ohmmeter, measure the resistance between
the terminals (NE(+) - NE(-)).
Pickup coil resistance (Cold):
370-550 W
Pickup coil resistance (Hot):
475-650 W
If the resistance is not as specified, replace the distrib-
utor housing assembly.
3. REMOVE DISTRIBUTOR CAP
4. REMOVE DISTRIBUTOR ROTOR
5. REMOVE IGNITION COIL DUST COVER
7. INSPECT PRIMARY COIL RESISTANCE
Using an ohmmeter, measure the resistance between
positive (+) and negative (-) terminals.
Primary coil resistance (Cold):
0.36-0.55 W
Primary coil resistance (Hot):
0.45 - 0.65 W
If the resistance is not as specified, replace the igni-
tion coil.
6. INSPECT AIR GAP
Using a thickness gauge, measure the gap between
the signal rotor and pickup coil projection.
Air gap:
0.2 - 0.4 mm (0.008 - 0.016 in.)
If the air gap is not as specified, replace the distributor
housing assembly.
Ignition Coil
DISTRIBUTOR INSPECTION
NOTICE: ’Cold’ and ’Hot’ in the following sentences ex-
press the temperature of the coils themselves. ”Cold” is
from -10°C (14°F) to 50°C (122°F) and ”Hot” is from
50°C (122°F) to 100°C (212°F).
1. DISCONNECT DISTRIBUTOR CONNECTORS
Distributor
-IGNITION SYSTEM ON-VEHICLE INSPECTION
IG-8

9. 8. INSPECT SECONDARY COIL RESISTANCE
Using ohmmeter, measure the resistance between the
positive (+) and high-tension terminals.
Secondary coil resistance (Cold):
9.0 - 15.4 kW
Secondary coil resistance (Hot):
11.4 - 18.1 kW
If the resistance is not as specified, replace the igni-
tion coil.
9. REINSTALL IGNITION COIL DUST COVER
10. REINSTALL DISTRIBUTOR ROTOR
11. REINSTALL DISTRIBUTOR CAP
12. RECONNECT DISTRIBUTOR CONNECTORS
IGNITER INSPECTION
(See procedure Spark Test on page IG-5 )
-IGNITION SYSTEM ON-VEHICLE INSPECTION
IG-9

10. DISTRIBUTOR
DISTRIBUTOR REMOVAL
1. DISCONNECT NEGATIVE TERMINAL CABLE FROM
BATTERY
CAUTION (w/ SRS): Work must be started after 80 sec-
onds from the time the ignition switch is turned to the
’LOCK’ position and the negative (-) terminal cable is
disconnected from the battery.
2. DISCONNECT DISTRIBUTOR CONNECTORS
3. DISCONNECT HIGH-TENSION CORDS FROM
SPARK PLUGS
(a) Disconnect the cord clamp from the cylinder head
cover.
(b) Disconnect the 4 high-tension cords from the spark
plugs.
Disconnect the high - tension cords at the rubber
boot. Do not pull on the high-tension cords.
NOTICE: Pulling on or bending the cords may damage the
conductor inside.
4. REMOVE DISTRIBUTOR
(a) Remove the 2 bolts, and pull out the distributor.
(b) Remove the O-ring from the distributor housing.
-IGNITION SYSTEM DISTRIBUTOR
IG-10

11. DISTRIBUTOR DISASSEMBLY
(See Components for Disassembly and Assembly)
1. REMOVE DISTRIBUTOR CAP AND ROTOR
2. REMOVE IGNITION COIL DUST COVER
3. REMOVE PACKING
4. REMOVE IGNITION COIL
(a) Remove the 2 nuts, and disconnect the wires from the
terminals of the ignition coil.
COMPONENTS FOR DISASSEMBLY AND
ASSEMBLY
-IGNITION SYSTEM DISTRIBUTOR
IG-1 1

12. DISTRIBUTOR ASSEMBLY
(See Components for Disassembly and Assembly)
1. INSTALL DISTRIBUTOR WIRE
(a) Connect the connector to the condenser, and install
the wire.
(b) Install the grommet of the wire to the housing.
2. INSTALL IGNITION COIL
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the ignition coil installing sur-
face of the housing as shown in the illustration.
Seal packing:
Part No. 08826-00080 or equivalent
DISTRIBUTOR INSPECTION
INSPECT SHAFT
Turn the shaft, and check that it is not rough or worn.
If it feels rough or worn, replace the distributor hous-
ing assembly.
5. REMOVE DISTRIBUTOR WIRE
(a) Remove the grommet of wire to the housing.
(b) Disconnect the connector from the condenser, and
remove the wire.
(b) Remove the 4 screws and ignition coil.
-IGNITION SYSTEM DISTRIBUTOR
IG-12

13. NOTICE:
• When connecting the wires to the ignition coil,
insert both properly into their grooves found on the
side of the ignition coil.
• Be sure that the wires do not come into contact with
the signal rotor distributor housing.
4. INSTALL NEW PACKING
5. INSTALL IGNITION COIL DUST COVER
6. INSTALL ROTOR AND DISTRIBUTOR CAP
(a) Install the rotor.
(b) Install the cap and condenser with the 3 bolts.
(d) Connect the 2 wires to the terminals of the ignition
coil with the 2 nuts as shown.
(c) Install the ignition coil with the 4 screws.
-IGNITION SYSTEM DISTRIBUTOR
IG-13

14. DISTRIBUTOR INSTALLATION
1. SET NO.1 CYLINDER TO TDC/COMPRESSION
Turn the crankshaft clockwise, and position the slits
(A) and indentation (B) of the camshaft as shown in the illustration.
(d) Insert the distributor, aligning the protrusion of the
flange with that of the nut on the cylinder head cover.
(e) Lightly tighten the 2 bolts.
2. INSTALL DISTRIBUTOR
(a) Install a new O-ring to the distributor housing.
(b) Apply a light coat of engine oil on the O-ring.
(c) Align the protrusion on the housing with groove of the
coupling.
-IGNITION SYSTEM DISTRIBUTOR
IG-14

15. 3. .CONNECT HIGH-TENSION CORDS TO SPARK
PLUGS
Firing order:
1-3-4-2
4. CONNECT DISTRIBUTOR CONNECTORS
5. CONNECT NEGATIVE TERMINAL CABLE TO
BATTERY
6. WARM UP ENGINE
Allow the engine to warm up to normal operating
temperature.
7. CONNECT TACHOMETER
Connect the tester probe of a tachometer to terminal
IG(-) of the data link connector 1.
NOTICE:
• Never allow the tachometer terminal to touch
ground as it could reselt in damage to the igniter
and/or ignition coil.
• As some tachometers are not compatible with this
ignition system, we recommend that you confirm
the compatibility of your unit before use.
8. ADJUST IGNITION TIMING
(a) Using SST, connect terminals TE1 and E1 of the data
link connector 1.
SST 09843-18020
(b) Check the idle speed.
Idle speed:
M/T
750 ± 50 rpm
A/T
800 ± 50 rpm
(w/ Cooling fan OFF and transmission in neutral
position)
(c) Using a timing light, check the ignition timing.
Ignition timing:
10_ BTDC @ idle
(w/ Cooling fan OFF and transmission in neutral
position)
(d) Loosen the 2 bolts, and adjust by turning the distribu-
tor.
(e) Tighten the 2 bolts, and recheck the ignition timing.
Torque: 17 N-m (175 kgf-cm, 13 ft-lbf)
(f) Remove the SST from the data link connector 1.
SST 09843-18020
-IGNITION SYSTEM DISTRIBUTOR
IG-15

16. 9. FURTHER CHECK IGNITION TIMING
Check the ignition timing advance.
Ignition timing:
7 - 17_ BTDC @ idle
(w/ Cooling fan OFF and transmission in neutral
position)
HINT: The timing mark moves in a tange between 7_
and 17_.
10. DISCONNECT TACHOMETER AND TIMING LIGHT
FROM ENGINE
-IGNITION SYSTEM DISTRIBUTOR
IG-16

17. SERVICE SPECIFICATIONS
SERVICE DATA
0.2 - 0.4 mm (0.008 - 0.016 in.)
370 - 550W
475 - 650W
Air gap
Pickup coil resistance (NE(+) - NE(-)
0.36 - 0.55W
0.45 - 0.65W
9.0 - 15.4 kW
11.4 - 18.1 kW
TORQUE SPECIFICATIONS
W16EXR-U11
BPR5EY11
1.1 mm (0.043 in.)
w/ Terminals TE1 and E1 connected of DLC1
at cold
at hot
at cold
at hot
Spark plug x Cylinder head
Distributor x Cylinder head
High-tension
cord
Recommended spark plug
Secondary coil resistance
Primary coil resistance
Correct electrode gap
10° BTDC @ idle
25 kW per cord
Ignition timing
1-3-4-2
at cold
at hot
Part tightened
Ignition coil
Firing order
Spark plug
Distributor
Resistance
ND
NGK
kgf-cm
Limit
ft-lbf
180
175
N-m
-IGNITION SYSTEM SERVICE SPECIFICATIONS
IG-17