Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Toyota Celica 1988-1989.1993-1994.2000 Approved Toyota Celica 1993 REMOVE_I
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N - REMOVE/INSTALL/OVERHAUL
1993 Toyota Celica
1993 ENGINE PERFORMANCE
Removal, Overhaul & Installation
Celica
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.
CAUTION: When battery is disconnected, vehicle computer and memory
systems may lose memory data. Driveability problems may
exist until computer systems have completed a relearn
cycle. If vehicle is equipped with air bag(s), after
disconnecting negative battery cable, wait a minimum of 2
minutes before working on vehicle.
IGNITION SYSTEM
DISTRIBUTOR
NOTE: For timing specifications and procedures, see the appropriate
D - ADJUSTMENTS - 4-CYL article in this section.
Removal (Celica)
1) Disconnect negative battery cable. On 2.0L turbo 3S-GTE,
remove intercooler. See TURBOCHARGER under AIR INDUCTION SYSTEM.
2) On all models, disconnect spark plug wires from spark
plugs (and from ignition coil on 3S-GTE). Disconnect distributor
electrical connector. Scribe relationship mark between distributor
flange and cylinder head. Remove distributor hold-down bolt(s) or
nut(s). Remove distributor. Remove "O" ring from distributor housing
and discard.
Fig. 1: Aligning Distributor Cut-Out Marks (Typical)
Courtesy of Toyota Motor Sales, U.S.A., Inc.
Overhaul
Only distributor cap, rotor and coil are serviceable. Pick-up
coil and distributor housing assembly are replaced as a unit.
Installation
1) Set cylinder No. 1 to TDC of compression stroke. Coat new
"O" ring with oil and install onto distributor housing. Align mark of
drive coupling with groove on distributor housing. See Fig. 1.
2) Install distributor to camshaft, aligning distributor
mounting flange hole slot with bolt hole on cylinder head. Snug
distributor hold-down bolt/nut, but DO NOT tighten. Connect
distributor wiring connector. Install spark plug wires.
3) To complete installation, reverse removal procedure.
Connect negative battery cable. Start engine and set ignition timing.
Tighten distributor hold-down bolt/nut(s). See TORQUE SPECIFICATIONS
at the end of this article.
FUEL SYSTEM
FUEL SYSTEM PRESSURE RELEASE
WARNING: High fuel pressure may be present in fuel lines and
component parts. Before opening system for testing
purposes or component replacement, relieve fuel pressure.
DO NOT allow fuel to flow onto engine or electrical
parts. Whenever possible, release fuel pressure at fuel
filter fitting.
Disconnect negative battery 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.
CHECKING FOR FUEL LEAKS
NOTE: After replacing fuel system components or performing fuel
system maintenance, verify there are no fuel leaks.
Using Diagnosis Check Wire (SST09843-18020), connect Data
Link Connector 1 (DLC1) terminals +B and FP. Turn ignition on, with
engine off. When fuel return hose is pinched (DO NOT bend hose, as it
may cause cracking), fuel pressure within high pressure line will rise
to approximately 57 psi (4 kg/cm ). Pinch fuel return hose and verify
there are no fuel system leaks. When inspection is completed, turn
ignition off and remove diagnosis check wire from DLC1.
COLD START INJECTOR
Removal & Installation (Celica 2.0L 3S-GTE)
1) Locate cold start injector under throttle body. Disconnect
negative battery cable. Remove throttle body. See THROTTLE BODY.
Disconnect cold start injector connector. Slowly remove cold start
injector pipe 2 union bolts and 4 gaskets, using care not to spill
fuel. Remove cold start injector and gasket.
2) Install cold start injector with a NEW gasket. Tighten
bolts to 52 INCH lbs. (5.9 N.m). Install injector pipe, 2 union bolts
and 4 NEW gaskets. Tighten union bolt to 108 INCH lbs. (12 N.m).
Connect cold start injector connector and throttle body. See THROTTLE
BODY. Connect negative battery cable. Check for fuel leakage. See
CHECKING FOR FUEL LEAKS.
FUEL PUMP
Removal (Celica 2.0L 3S-GTE)
1) Disconnect negative battery cable. Remove gas cap from
filler tube to relieve fuel tank pressure. Release fuel pressure at
fuel filter. See FUEL SYSTEM PRESSURE RELEASE. In luggage compartment,
locate floor service hole cover. Remove wiring protector and
disconnect fuel pump and fuel sender electrical connectors at floor
service hole cover.
2) Remove service hole cover. Remove screws attaching fuel
sender gauge to tank and remove fuel sender gauge. Drain fuel from
fuel tank into container. Raise vehicle enough to enable fuel tank
removal.
3) Remove left rear wheel. Remove fuel tank plastic
protector. Remove fuel tank filler pipe protector. Disconnect filler
pipe from fuel tank. Disconnect fuel outlet hose, return hose and fuel
evaporation hose from tank tubes. Support fuel tank and remove
retaining straps. Lower tank. Remove fuel evaporation bent tube.
Remove fuel pump assembly from tank.
4) Pull lower end of fuel pump (with filter) away from
bracket. Remove 2 nuts securing fuel pump wires to fuel pump and
disconnect wires. Disconnect fuel hose from pump and remove fuel pump.
Using small blade screwdriver, remove clip retaining filter to pump.
Installation
1) 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). Install fuel evaporation bent tube.
Tighten fuel evaporation bent tube-to-tank retaining screws to 13 INCH
lbs. (1.5 N.m). Tighten fuel evaporation bent tube-to-fuel pump
bracket to 26 INCH lbs. (2.9 N.m).
2) Install fuel tank to body. Tighten fuel tank band nuts to
16 ft. lbs. (22 N.m). Install fuel hoses. Tighten outlet hose to 22
ft. lbs. (30 N.m). Install fuel sender gauge with NEW gasket. Tighten
fuel sender bracket-to-tank nuts to 13 INCH lbs. (1.5 N.m). To
complete installation, reverse removal procedure. Check for fuel
leakage. See CHECKING FOR FUEL LEAKS.
Removal & Installation (Celica 1.6L 4A-FE & 2.2L 5S-FE)
1) Disconnect negative battery cable. Remove gas cap from
filler tube to relieve fuel tank pressure. Remove rear seat cushion.
Remove fuel pump hole cover. Disconnect fuel pump and fuel sender
electrical connector. Release fuel pressure at filter. See FUEL SYSTEM
PRESSURE RELEASE.
2) Disconnect fuel outlet line and fuel return line 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. On Corolla, tighten fuel pump bracket-to-tank nuts to 34 INCH
lbs. (3.8 N.m). On other models, tighten fuel pump bracket-to-tank
nuts to 26 INCH lbs. (2.9 N.m). On all models, tighten fuel pump
outlet line to 22 ft. lbs. (30 N.m). Check for fuel leakage. See
CHECKING FOR FUEL LEAKS.
FUEL INJECTORS & FUEL RAILS
NOTE: Install NEW grommets and "O" rings when replacing fuel
injectors or reinstalling old injectors. Verify injectors
rotate smoothly in injector ports and in fuel rail. If
injectors do not rotate smoothly, check "O" rings for proper
installation.
Removal (Celica 2.2L 5S-FE)
1) Disconnect negative battery cable. Release fuel pressure
at fuel filter. See FUEL SYSTEM PRESSURE RELEASE. Drain engine
coolant. Disconnect throttle cable(s) from throttle body. Remove air
temperature sensor connector and cruise control cable clamp from air
cleaner housing.
2) Loosen duct hose clamp from throttle body. Remove air
cleaner cap, resonator and duct hose as an assembly. Disconnect
Throttle Position Sensor (TPS) connector and Idle Air Control (IAC)
valve connector from throttle body. Mark positions of all vacuum hoses
connected to throttle body for reassembly purposes, and remove vacuum
hoses from throttle body.
3) Remove 4 throttle body mounting bolts. Remove coolant
hoses from throttle body and remove throttle body. Remove power
steering vacuum hoses from tubing lines near intake manifold. Mark
positions and remove 2 vacuum hoses from EVAP-Thermal Vacuum Valve
(TVV) near distributor. Remove EGR temperature sensor harness
connector (if equipped).
4) Mark positions and remove 2 vacuum hoses from EGR VSV near
bottom of intake manifold. Remove vacuum hose from canister. Remove
vacuum hoses tubing retaining clamp near bottom of intake manifold.
Disconnect EGR pipe fittings. Remove EGR valve, EGR vacuum modulator
and related vacuum hoses.
5) Remove vacuum hoses from intake manifold to brake booster,
vacuum sensor, and A/C magnet switch VSV connector. Remove engine
ground wire from intake manifold. Disconnect knock sensor and EGR VSV
harness connectors. Remove engine harness clamps from brackets on
intake manifold. Remove 2 intake manifold support braces. Remove
intake manifold.
6) Disconnect fuel injector harness connectors. Disconnect
fuel return hose from fuel return pipe. Remove fuel inlet hose by
removing pressure pulsation damper and washer gaskets.
7) Remove 2 fuel rail mounting bolts. Gently twist each
injector to ease removal. Remove fuel rail with 4 injectors attached,
using care not to drop injectors from rail. Replace injector if
dropped. Remove 4 injector insulators and 2 rail spacers from intake
manifold. Remove fuel injectors from fuel rail by gently pulling.
Remove pressure regulator from fuel rail. See Fig. 2.
Installation
1) Install NEW grommets and "O" rings onto injectors. Apply
light coat of gasoline to "O" rings and install injectors to fuel
rail. See Fig. 5. Install 4 NEW injector insulators and 2 rail spacers
in position on cylinder head.
2) Place injectors with attached fuel rail into injector
ports on cylinder head. Verify injectors rotate smoothly. If injectors
do not rotate smoothly, check "O" rings for binding and for proper
installation. Replace "O" ring(s) as required. Verify injector
electrical connectors are positioned upward and on cam cover side of
fuel rail.
3) Install fuel rail bolts. Install fuel inlet pipe and
pulsation damper. To complete installation, reverse removal procedure.
Tighten all nuts and bolts to specification. See TORQUE
SPECIFICATIONS. Fill engine with coolant. Engine coolant capacity is
6.7 qts. (6.3L). Check for fuel leakage. See CHECKING FOR FUEL LEAKS.
Fig. 2: Locating Fuel Injection Components (Celica - 2.2L 5S-FE)
Courtesy of Toyota Motor Sales, U.S.A.
Fig. 3: Proper Injector Installation Into Fuel Rail (Typical)
Courtesy of Toyota Motor Sales, U.S.A., Inc.
Removal (Celica 1.6L 4A-FE)
1) Disconnect negative battery cable. Disconnect vacuum hose
and fuel return hose from fuel pressure regulator. Release fuel
pressure. See FUEL SYSTEM PRESSURE RELEASE.
2) Disconnect fuel inlet pipe from fuel rail by removing fuel
pipe union bolt and 2 washer gaskets. Disconnect fuel injector harness
connectors. Remove 2 fuel rail mounting bolts and carefully lift fuel
rail with injectors attached.
3) Remove 4 insulators and 2 fuel rail spacers from cylinder
head. Pull injectors from fuel rail. Remove "O" ring and grommet from
each fuel injector.
Installation
1) Install NEW grommet to each fuel injector. Apply a light
coat of gasoline to NEW "O" ring and install onto injector. Apply a
light coat of gasoline to "O" ring on injector to ease installation
into fuel rail.
2) Install fuel injectors into fuel rail by turning/twisting
fuel injector from left to right in order to bottom injector into fuel
rail. See Fig. 3. Place 4 NEW insulators and 2 NEW spacers into
position on cylinder head. Insert fuel rail/injector assembly into
insulators on cylinder head. Verify fuel injectors rotate smoothly in
insulators.
3) Position fuel injector electrical connectors upward.
Install fuel rail mounting bolts and tighten to 11 ft. lbs. (15 N.m).
Connect fuel inlet hose to fuel rail using 2 NEW washer gaskets.
Tighten fuel inlet pipe union bolt to 22 ft. lbs. (30 N.m).
4) Connect fuel injector connectors. Connect fuel return hose
and vacuum hose to fuel pressure regulator. Connect negative battery
cable. Check for fuel leakage. See CHECKING FOR FUEL LEAKS.
Removal (Celica 2.0L 3S-GTE)
1) Disconnect negative battery cable. Drain coolant from
engine. Remove intercooler and throttle body. See THROTTLE BODY.
Remove charcoal canister. Remove EGR VSV and vacuum modulator. Remove
EGR valve and pipe. Remove cold start injector fuel pipe and cold tart
injector. See COLD START INJECTOR.
2) Remove air hose and coolant hoses by-pass pipe. Disconnect
injector connectors. Disconnect engine wiring harness from intake
manifold. Disconnect fuel pressure regulator vacuum hose. Release fuel
pressure at filter, and remove fuel inlet hose. See FUEL SYSTEM
PRESSURE RELEASE. Disconnect fuel return hose from pressure regulator.
3) Remove 3 bolts retaining fuel rail to intake manifold.
Remove fuel rail with attached fuel injectors. Note position of 3
mounting spacers for reassembly reference. Remove 3 mounting spacers
and any remaining injector insulators from intake manifold. Disconnect
fuel inlet hose pipe and one mounting bolt from fuel rail.
4) Remove 4 small bolts retaining fuel injector cover to fuel
rail. Apply gasoline to both ends of injector to ease removal from
fuel rail. Pull injectors from rail. Loosen lock nut, and remove fuel
pressure regulator from fuel rail.
Installation
1) Apply light coat of gasoline to NEW "O" rings and install
2 "O" rings to each injector. Install each injector into fuel rail so
injector electrical connector is opposite injector cover bolt hole.
See Fig. 4.
2) Install fuel pressure regulator to fuel rail using hand
pressure to fully bottom unit into rail. Turn regulator
counterclockwise until vacuum pipe aligns with rail and fuel return
pipe is 180 degrees from fuel rail. Tighten lock nut to 22 ft. lbs.
(30 N.m).
3) Install NEW insulator to each injector and install
injector cover. Tighten 4 cover bolts to 69 INCH lbs. (7.8 N.m).
Connect fuel inlet pipe to fuel rail. Tighten fuel pipe union bolt to
22 ft. lbs. (30 N.m), and fuel line mounting bolt to 69 INCH lbs. (7.8
N.m).
4) Install NEW insulator to each injector bottom. Position 3
fuel rail mounting spacers to intake manifold. Install fuel rail, with
attached injectors, into intake manifold injector recesses. Install 3
fuel rail mounting bolts and tighten to 14 ft. lbs. (19 N.m).
5) Connect fuel return hose and vacuum hose to pressure
regulator. Install wiring harness to intake manifold and position to
mounting bolts on timing belt cover. Connect Gray colored injector
connectors to No. 2 and 4 injectors. Connect Brown colored injector
connectors to No. 1 and 3 injectors.
6) To complete installation, reverse removal procedure.
Tighten all nuts and bolts to specification. See TORQUE
SPECIFICATIONS. After installation complete check for fuel leaks. See
CHECKING FOR FUEL LEAKS.
Fig. 4: Positioning Injector Connectors (Celica 3S-GTE)
Courtesy of Toyota Motor Sales, U.S.A., Inc.
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
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