Toyota Tercel 1984-1994 Repair Guide

Parts Replacement

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The two most commonly replaced parts in the distributor (aside from the cap and rotor as maintenance) will be the signal generator and the igniter. Replacement of any internal piece usually requires removal of the distributor from the engine.

The distributor on some engines contain no replaceable parts except the ignition coil. Any other failed item in the distributor requires replacement of the complete unit.

REMOVAL & INSTALLATION



See Figures 1, 2 and 3

Distributor

WARNING
Once the distributor is removed, the engine should not be turned or moved out of position. Should this occur, please refer to the Distributor procedures of Engine & Engine Rebuilding .



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Fig. Fig. 1: Disconnect all of the distributor electrical connections



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Fig. Fig. 2: Mark the distributor position before removing it

  1. Label and disconnect the coil and spark plug wiring at the distributor cap.
  2.  
  3. Disconnect the distributor wire at its connector.
  4.  
  5. Remove the distributor hold down bolts. Before moving or disturbing the distributor, mark the position of the distributor relative to the engine. Use a marker or tape so the mark doesn't rub off during the handling of the case.
  6.  



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Fig. Fig. 3: Once the holddown bolt has been removed, the distributor can be removed from the engine

  1. Remove the distributor from the engine.
  2.  

To install:
  1. If the engine has not been moved out of position, align the rotor with the mark you made earlier and reinstall the distributor. Position it carefully and make sure the drive gear engages properly within the engine. Complete the installation by following the steps above in reverse order. For complete reinstallation instructions, refer to the Distributor procedures in Engine & Engine Rebuilding .
  2.  

Ignition Coil, Igniter and Pickup Coil Assembly

See Figures 4, 5, 6, 7 and 8

Review the complete service procedure before this repair. Note position and routing of all internal distributor assembly wiring.

  1. Remove the distributor as outlined above. Make certain the negative battery cable is disconnected before beginning the work.
  2.  
  3. Remove the distributor cap and rotor.
  4.  
  5. Remove the dust cover over the distributor components and remove the dust cover over the ignition coil.
  6.  
  7. Remove the nuts and disconnect the wiring from the ignition coil.
  8.  



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Fig. Fig. 4: Removing the ignition coil attaching screws

  1. Remove the four screws and remove the ignition coil from the distributor.
  2.  
  3. At the igniter terminals, disconnect the wiring from the connecting points.
  4.  



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Fig. Fig. 5: Removing the igniter

  1. Loosen and remove the two screws holding the igniter and remove it from the distributor.
  2.  



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Fig. Fig. 6: Carefully pry the signal rotor off the shaft

  1. If the signal rotor is to be replaced, use a screwdriver and CAREFULLY pry the rotor and spring up and off the shaft. When replacing the rotor, use a small bearing driver or long socket to fit over the shaft on top of the signal rotor. Tap gently; the force will be equally distributed and the rotor will slide evenly into place.
  2.  



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Fig. Fig. 7: Removing the breaker plate with the pickup coil

At this point of the service procedure, the breaker plate with the signal generator (pick-up coil) can be removed from the distributor housing by removing the retaining screws.

To install:
  1. Install the igniter and connect its wiring. Pay particular attention to the correct routing of the wiring within the housing. There is one correct position only; any other wiring placements risk damage.
  2.  



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Fig. Fig. 8: Secure the pickup coil wires in the clips, allowing sufficient slack

  1. Install the ignition coil and secure its wiring. Again, watch the wiring positions.
  2.  
  3. Reinstall the dust covers, the packing and distributor rotor.
  4.  
  5. Reinstall the distributor and set the engine timing.
  6.  

 
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