Toyota MR2 1ZZ Coil on Plug Kit 91-95 Toyota MR2, applicable for Gen 2 and Gen 3 **BGB service manual highly recommended**

Install time: 2 - 3 hours

In the Box: • (1) 430 SS Crank trigger wheel • (1) Crank trigger adapter • (1) Crank sensor mount with SS bolts • (2) Crank sensor mounting spacers • (1) 1ZZ coil adapter bracket with SS bolts • (4) Short M8 SS allen head bolts and washers • (2) Long M8 SS allen head bolts • (2) Cherry hall sensor and pull up resistors • (1) Cam wheel trigger assembly • (1) Cam wheel cover plate • (2) M10 allen head bolts

Tools: • Socket driver • 10mm socket • 7/16 socket • 8mm allen socket • 6mm allen socket • 5mm allen socket

Instructions: 1. Safely raise and support rear of vehicle, remove RH rear wheel. This will allow access to the engine crank

pulley. Bring cylinder #1 to top dead center (TDC), we highly recommend using a dial indicator for this process as the OEM cover can vary roughly 1 to 3 degrees from true TDC. (Fig 1)

2. Remove the (2) M6 bolts using a 10mm socket on the oil pump assembly. (Fig 2) 3. Install crank trigger wheel adapter using 6mm allen socket, tighten to 33 ft/lbs. Tip: Clean out the threads on

your crank pulley before installing supplied M8x1.25-25mm bolts. (Fig 3) 4. Install crank trigger wheel on the crank adapter. Finger tighten supplied M8x1.25-16mm length bolts with loc

washers. (Fig 4) 5. Install crank sensor adapter. The M6x1-65mm bolt will locate towards the top of the engine with the longer

spacer. The M6x1-70mm bolt and shorter spacer go below. Align with trigger wheel and tighten to 69 in-lbs using a 5mm allen head socket. (Fig 5)

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6. Thread the sensor into the crank sensor adapter. Bring it close to the trigger wheel and align it with the rising edge of the nearest tooth. Tighten the trigger wheel assembly using a 6mm allen head socket to 33 ft/lbs. If the crank and trigger wheel assembly moved during this turn, then crank clockwise until you reach the same tooth for TDC, marking this tooth with a sharpie is helpful. Finally, touch the sensor to the crank trigger tooth and then back the sensor off 2 full revolutions. This is the recommended spec from Cherry hall which is roughly 0.062”. (Fig 6 & 7)

7. Remove the distributor assembly, please follow the BGB for this procedure. (Fig 8) 8. Install cam trigger assembly into the intake cam key. Be sure the cam trigger is in the correct orientation, as

the trigger is slightly offset. (Fig 9 & 10) 9. Install cam trigger cover. Tighten supplied M10 bolts using 8mm allen head socket to 29 ft/lbs. Finally, thread

Cherry hall sensor until it touches the cam wheel, then turn it counterclockwise 2 full revolutions. This will set the gap at 0.062”. Then tighten sensor jam nut. (Fig 11 & 12)

10. Remove the 3 bolts located in the center of the valve cover. Then install the 1zz coil adapter plate using supplied hardware. The longest M6x1 bolt will be used on cylinder 1. Tighten the 1/4-20 nuts on the 1zz adapter plate to set the clinching studs, then remove the nuts. (Fig 13)

11. Install the 1zz coils and tighten 1/4-20 nuts, do not over tighten nuts. Finally, install coil number 1 with the 1/2” spacer below the coil and M6x1 allen head bolt. This completes the mechanical installation of the 1zz coil on plug kit. (Fig 14 & 15)

For wiring specifications please reference Cherry hall part number GS1007, Cherry hall is now ZF electronics. Please see the link for wiring specifications: http://switches-sensors.zf.com/us/wp-content/uploads/sites/7/2012/05/Datasheet_GS1005-GS1007_EN_29_11_17.pdf

The sensors require 2.4K ohm pull up resistors which are supplied with the kit.

The following instructions are specific to the AEM PNP system for the Toyota MR2. These may be helpful for other EMS, but are not specific to those systems. Racer X Fabrication is not responsible for EMS calibration or setup files. We suggest having a thorough understanding of your specific system before attempting the installation.

We suggest wiring the 12v+ together, wire the grounds together, and the IGF together. The IG trigger wires go to the following pins on the AEM: 18A: Coil 3 19A: Coil 2 20A: Coil 1 21A: Coil 5 (coil 4, but AEM calls it coil 5)

For reference if your looking at the 1zz coil, from left to right the pins are: pin 1: Ground pin 2: IGT (ignition trigger) pin 3: IGF (ignition feed back) Not used. pin 4: 12v+

The AEM settings are as follows: You must activate all the coils Options—>coil active coils: 1,2,3 and 5 (Each coil must be activated)

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Change the ignition to coils: Ignition-->advanced ignition-->coil dwell setup-->coil dwell wizard select: Toyota (04-up) tC/xB/xA/Prius/Echo coils

Setup the proper phasing for the coils: Ignition-->advanced ignition-->ignition phasing-->options ign phasing Use the following settings: ign tooth 1: 21.50 ign tooth 2: 15.50 ign tooth 3: 3.50 ign tooth 5: 9.50

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Now you need to change the cam/crank sensor settings: setup-->cam/crank sensors-->adv cam/crank-->advanced pickups Fuel teeth: 24 Spark teeth: 24 Ign range: 3

Change: Crank H sens below: 0 Crank L sens above: 0

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To get your tach working you will need to wire into a Low side input on the AEM. I used LS #7, you need to remember the output you will use it correlates to a number in the AEM manual that will need to be used later.

For the AEM you need to go to: setup-->advanced setup-->tacho/speedo control-->options tach speedo Tacho: 4 (this is also directly affected by the trigger wheel your using) Tacho output: 2 (this is number is specifically for the LS output you select)

More info on tach setup: The tacho number is calculated using the following formula: Tacho = Crank Teeth / (Required Output Pulses/Rev x 2)

Tacho output table for LS output: LS#3 = 128 LS#12 = 64 LS#11 = 32 LS#10 = 16 LS#9 = 8 LS#8 = 4 LS#7 = 2 LS#4 = 1

The crank signal will need to be wired into the AEM crank sensor which is pin 4A The cam signal will need to be wired into the AEM crank sensor which is pin 5A

You will be changing from the OEM magnatic sensor to a hall sensor so you will have to perform a jumper change on the AEM EMS board itself inside the box. The jumper your looking for is JPT 1 for the crank and JPT 2 for the cam. If you are only using the crank then do not move the cam jumper.

The setup procedure for the AEM EMS is complete. While cranking your car you should see that its syncing properly. Which will occur on sync tooth #23.

Make sure you check your timing with a timing light when completed with the installation and verify the settings in your AEM.

Questions, comments, or concerns? Email tech@racerxfabrication.com.

© 2018 Racer X Fabrication

© 2018 Racer X Fabrication

© 2018 Racer X Fabrication

© 2018 Racer X Fabrication