TOYOTA SUPRA 1986 Service User Guide

TURBOCHARGER REMOVAL
Installation is in the reverse order of removal.
1. DRAIN ENGINE COOLANT
2. REMOVE ENGINE UNDER COVER
3. DISCONNECT CRUISE CONTROL ACTUATOR CABLE
FROM THROTTLE BODY
4. REMOVE NO.1 AIR HOSE
5. REMOVE AIR CLEANER DUCT
6. REMOVE AIR CLEANER AND MAF METER ASSEMBLY
(a) Remove the 3 bolts.
(b) Loosen the hose clamp, disconnect the air hose from the
intake air connector.
(c) Disconnect the MAF meter wire from the clamp on the air
cleaner case.
(d) Disconnect the MAF meter connector, and remove the air
cleaner and MAF meter assembly. EG±150
± ENGINETURBOCHARGER SYSTEM (2JZ±GTE)

7. DISCONNECT THEFT DETERRENT HORN FROM BODY
8. REMOVE FRONT LOWER ARM BRACKET STAY
Remove the 2 bolts, nut, plate washer and arm bracket stay.
Torque:
Bolts
44 NVm (450 kgfVcm, 33 ftVlbf)
Nut
59 NVm (600 kgfVcm, 43 ftVlbf)
9. REMOVE UPPER FRONT CROSSMEMBER EXTENSION
Remove the 2 bolts, 2 nuts and crossmember extension.
Torque:
Bolts
29 NVm (300 kgfVcm, 22 ftVlbf)
Nuts
33 NVm (340 kgfVcm, 25 ftVlbf)
10. REMOVE NO.2 FRONT EXHAUST PIPE
(a) Remove the 2 bolts and nuts holding the front exhaust pipe
to the No.2 front exhaust pipe.
Torque: 58 NVm (590 kgfVcm, 43 ftVlbf)
(b) Remove the 2 bolts and pipe support bracket.
Torque: 43 NVm (440 kgfVcm, 32 ftVlbf)
(c) Disconnect the front exhaust pipe from the No.2 exhaust
pipe. Remove the gasket.
INSTALLATION HINT: Use a new gasket.
(d) Remove the 3 nuts, No.2 front exhaust pipe and gasket.
INSTALLATION HINT: Use a new gasket and 3 new nuts.
Torque: 62 NVm (630 kgfVcm, 46 ftVlbf)
11. REMOVE HEAT INSULATOR FOR NO.2 FRONT EXHAUST
PIPE
Remove the 2 bolts, 2 nuts and heat insulator.
12. DISCONNECT A/T OIL COOLER TUBES FROM ENGINE
(a) Remove the bolt and tube clamp, and disconnect the oil
cooler tubes from the bracket (front side) on the generator.
(b) Remove the bolt and tube clamp, and disconnect the oil
cooler tubes from the bracket (rear side) on the cylinder
block.
(c) Remove the bolt and tube bracket (rear side) from the
cylinder block.
± ENGINETURBOCHARGER SYSTEM (2JZ±GTE)EG±151

13. DISCONNECT ENGINE WIRE PROTECTOR FROM BODY
Remove the 2 bolts, and disconnect the wire protector from
the body.
14. DISCONNECT HOSES
Disconnect these hoses:
(1) Heater hose from No.3 water bypass pipe
(2) EVAP hose from No.1 vacuum pipe
15. DISCONNECT IAC VALVE PIPE FROM NO.2 AIR TUBE
(a) Disconnect the engine wire from the clamp.
(b) Disconnect these hoses:
(1) Air hose (from No.1 vacuum pipe) from IAC valve pipe
(2) Air hose from No.2 air tube
(c) Disconnect the IAC valve pipe from the clamp.
16. DISCONNECT NO.1 VACUUM PIPE FROM AIR TUBES
(a) Disconnect these connectors:
(1) VSV connector for intake air control valve
(2) VSV connector for exhaust bypass valve
(b) Disconnect the engine wire from the 3 clamps.
(c) Disconnect these hoses:
(1) Air hose from No.4 air tube
(2) Air hose from No.1 air tube
(3) Air hose (from VSV for waste gate valve) from vacuum
pipe
(4) Air hose (from VSV for exhaust gas control valve) from
vacuum pipe
(5) Vacuum hose (from air bypass valve) from No.1 air tube
(6) 2 air hoses (from VSV for exhaust bypass valve) from
vacuum pipe
(7) Air hose (from No.2 air tube) from vacuum pipe
(8) Air hose from VSV for intake air control valve
(9) 2 air hoses (from pressure tank) from vacuum pipe
(d) Remove the 3 bolts, and disconnect the vacuum pipe from
the air tubes. EG±152
± ENGINETURBOCHARGER SYSTEM (2JZ±GTE)

17. REMOVE VSV ASSEMBLY
(a) Disconnect these hoses:
(1) Air hose from actuator for waste gate valve
(2) Air hose from actuator for exhaust gas control valve
(3) Air hose from hose clamp
(4) Engine wire from wire clamp
(b) Remove the 2 bolts.
(c) Disconnect the 2 VSV connectors, and remove the VSV
assembly.
18. REMOVE AIR TUBES AND INTAKE AIR CONNECTOR
(a) Disconnect the connector and hoses:
(1) Crankshaft position sensor connector from clamp
(2) Water bypass hose (from water pump) from No.1 turbo
water pipe
(3) Water bypass hose (from water outlet) from No.1 turbo
water pipe
(4) Water bypass hose (from water outlet) from No.2 turbo
water pipe
(b) Remove the bolt, and disconnect the No.2 turbo water pipe
from the No.4 air tube.
(c) Remove the 2 bolts, and disconnect the No.1 air tube from
the No.1 turbocharger. Remove the gasket.
INSTALLATION HINT: Use a new gasket.
Torque: 21 NVm (210 kgfVcm, 15 ftVlbf)
(d) Remove the 2 bolts holding the No.4 air tube to the No.1
turbocharger. Remove the gasket.
INSTALLATION HINT: Use a new gasket.
Torque: 21 NVm (210 kgfVcm, 15 ftVlbf)
(e) Disconnect these hoses, and remove the No.4 air tube and
air bypass valve assembly.
(1) Air hose from No.4 air tube
(2) Air hose from intake air connector
± ENGINETURBOCHARGER SYSTEM (2JZ±GTE)EG±153

(f) Remove the 2 nuts, intake air control valve and gasket.
INSTALLATION HINT: Use a new gasket.
Torque: 21 NVm (210 kgfVcm, 15 ftVlbf)
(g) D i s connect these hoses, and remove the intake air
connector and No.1 air tube assembly.
(1) Air hose from No.2 air tube
(2) PCV hose from No.2 cylinder head cover
19. REMOVE AIR INLET DUCT
Remove the bolt, 2 nuts, cable bracket and air inlet duct.
20. REMOVE HEAT INSULATOR FOR TURBOCHARGER
Remove the 4 bolts and heat insulator.
21. REMOVE EXHAUST BYPASS PIPE
Remove the 4 nuts, bypass pipe and 2 gaskets.
INSTALLATION HINT: Use 2 new gaskets and 4 new nuts.
Torque: 25 NVm (250 kgfVcm, 18 ftVlbf)
22. REMOVE EXHAUST GAS CONTROL VALVE STAY
Remove the bolt, nut and valve stay.
Torque: 43 NVm (440 kgfVcm, 32 ftVlbf)
EG±154± ENGINETURBOCHARGER SYSTEM (2JZ±GTE)

23. REMOVE MAIN HEATED OXYGEN SENSOR
(a) Disconnect the oxygen sensor connector.
(b) Remove the 2 nuts, oxygen sensor and gasket.
INSTALLATION HINT: Use a new gasket and 2 new nuts.
Torque: 20 NVm (200 kgfVcm, 14 ftVlbf)
24. REMOVE EXHAUST GAS CONTROL VALVE
Remove the 3 nuts, control valve and 2 gaskets.
NOTICE: The control valve is ceramic. Do not drop or knock
the control valve.
INSTALLATION HINT: Use 2 new gaskets and 3 new nuts.
Torque: 69 NVm (700 kgfVcm, 51 ftVlbf)
25. REMOVE NO.1 TURBOCHARGER STAY
Remove the bolt, nut and turbocharger stay.
Torque: 43 NVm (440 kgfVcm, 32 ftVlbf)
26. REMOVE NO.2 TURBOCHARGER STAY
Remove the bolt, nut and turbocharger stay.
INSTALLATION HINT: Install the turbocharger stay and No.1
turbo oil pipe clamp with the bolt and nut.
Torque: 43 NVm (440 kgfVcm, 32 ftVlbf)
27. REMOVE NO.1 TURBO OIL PIPE
(a) Remove the union bolt holding the turbo oil pipe to the
cylinder block. Remove the 2 gaskets.
INSTALLATION HINT: Use 2 new gaskets.
Torque: 39 NVm (400 kgfVcm, 29 ftVlbf)
(b) Remove the 2 nuts, and disconnect the turbo oil pipe from
turbocharger. Remove the gasket.
INSTALLATION HINT:
wUse a new gasket.
wAlign the oil holes of the gasket and turbocharger
housing.
Torque: 21 NVm (210 kgfVcm, 15 ftVlbf)
(c) Disconnect the turbo oil hose from the turbo oil outlet on the
No.1 oil pan, and remove the turbo oil pipe.
28. REMOVE NO.2 TURBO OIL PIPE
(a) Remove the union bolt holding the turbo oil pipe to the
cylinder block. Remove the 2 gaskets.
INSTALLATION HINT: Use 2 new gaskets.
Torque: 39 NVm (400 kgfVcm, 29 ftVlbf)
± ENGINETURBOCHARGER SYSTEM (2JZ±GTE)EG±155

(b) Remove the 2 nuts, and disconnect the turbo oil pipe from
turbocharger. Remove the gasket.
INSTALLATION HINT:
wUse a new gasket.
wAlign the oil holes of the gasket and turbocharger
housing.
Torque: 21 NVm (210 kgfVcm, 15 ftVlbf)
(c) Disconnect the turbo oil hose from the turbo oil outlet on the
No.1 oil pan, and remove the turbo oil pipe.
29. REMOVE TURBOCHARGERS AND TURBINE OUTLET
ELBOW ASSEMBLY
(a) Disconnect these hoses:
(1) Heater hose (from No.3 water bypass pipe) from No.2
water bypass pipe
(2) Water bypass hose (from No.2 turbo water pipe) from
No.2 water bypass pipe
(b) Remove the 8 nuts holding the turbochargers to the exhaust
manifold.
INSTALLATION HINT:
wUse 8 new nuts.
wUniformly tighten the nuts in several passes.
Torque: 54 NVm (550 kgfVcm, 40 ftVlbf)
(c) Remove the 2 turbochargers and turbine outlet elbow
assembly.
(d) Remove the 2 gaskets.
INSTALLATION HINT: Use 2 new gaskets.
30. R E M O V E N O . 1 VACUUM PIPE FROM NO.2
TURBOCHARGER
Disconnect the 2 air hoses from the actuator for the exhaust
bypass valve, and remove the vacuum pipe.
31. REMOVE NO.2 AIR TUBE AND NO.3 WATER BYPASS
PIPE ASSEMBLY FROM NO.2 TURBOCHARGER
Remove the 2 bolts, the air tube, bypass pipe assembly and
gasket.
INSTALLATION HINT: Use a new gasket.
Torque: 21 NVm (210 kgfVcm, 15 ftVlbf)
EG±156± ENGINETURBOCHARGER SYSTEM (2JZ±GTE)

32. REMOVE EXHAUST MANIFOLD PLATE FROM TURBINE
OUTLET ELBOW
Remove the 2 bolts and manifold plate.
33. R E M O V E N O . 2 TURBO WATER PIPE FROM NO.2
TURBOCHARGER
Remove the 2 nuts, water pipe and gasket.
INSTALLATION HINT: Use a new gasket.
Torque: 8.8 NVm (90 kgfVcm, 78 in.Vlbf)
34. REMOVE BEARING HOUSING SIDE PLATE FROM NO.1
TURBOCHARGER
Remove the 2 nuts, housing plate and gasket.
INSTALLATION HINT: Use a new gasket.
Torque: 8.8 NVm (90 kgfVcm, 78 in.Vlbf)
35. R E M O V E N O . 1 TURBO WATER PIPE FROM NO.1
TURBOCHARGER
Remove the 2 nuts, water pipe and gasket.
INSTALLATION HINT: Use a new gasket.
Torque: 8.8 NVm (90 kgfVcm, 78 in.Vlbf)
36. REMOVE BEARING HOUSING SIDE PLATE FROM NO.2
TURBOCHARGER
Remove the 2 nuts, housing plate and gasket.
INSTALLATION HINT: Use a new gasket.
Torque: 8.8 NVm (90 kgfVcm, 78 in.Vlbf)
37. R E M O V E N O . 1 TURBOCHARGER FROM TURBINE
OUTLET ELBOW
Remove the 6 nuts, turbocharger and gasket.
INSTALLATION HINT:
wUse a new gasket and 6 new nuts.
wUniformly tighten the nuts in several passes.
Torque: 25 NVm (250 kgfVcm, 18 ftVlbf)
38. R E M O V E N O . 2 TURBOCHARGER FROM TURBINE
OUTLET ELBOW
Remove the 6 nuts, turbocharger and gasket.
INSTALLATION HINT:
wUse a new gasket and 6 new nuts.
wUniformly tighten the nuts in several passes.
Torque: 25 NVm (250 kgfVcm, 18 ftVlbf)
± ENGINETURBOCHARGER SYSTEM (2JZ±GTE)EG±157

TURBOCHARGER COMPONENTS
INSPECTION
Turbochargers
1. INSPECT TURBINE SHAFT ROTATION
Grasp the edge of the turbine wheel and turn it. Check that
the impeller wheel turns smoothly.
If the impeller wheel does not turn or if it turns with a drag, re-
place the turbocharger assembly.
2. INSPECT AXIAL PLAY OF TURBINE SHAFT
(a) Using a dial indicator, insert the needle of the dial indicator
into the air tube side.
(b) Move the turbine shaft in an axial direction, measure the axial
play of the turbine shaft.
Maximum axial play:
0.110 mm (0.0045 in.)
If the axial play is greater than maximum, replace the turbo-
charger assembly.
3. INSPECT RADIAL PLAY OF TURBINE SHAFT
(a) Using a dial indicator, insert the needle of the dial indicator
into the oil outlet hole and set it in the center of the turbine
shaft.
(b) Move the turbine shaft in a radial direction, measure the
radial play of the turbine shaft.
Maximum radial play:
0.162 mm (0.0064 in.)
If the axial play is greater than maximum, replace the turbo-
charger assembly.
4. INSPECT WASTE GATE VALVE OPERATION
(a) Disconnect the actuator air hose from the housing, and plug
the hose end.
(b) Using SST, apply approx. 120 kPa (1.22 kgf/cm
2, 17.4 psi) of
pressure to the actuator.
SST 09992±00241
(c) Move the actuator push rod, and check that the waste gate
valve is open.
If operation is not as specified, replace the No.1 turbocharger
assembly.
NOTICE: Never apply more than 187 kPa (1.91 kgf/cm2, 27.2
psi) of pressure to the actuator.
(d) Reconnect the actuator air hose to the housing. EG±158
± ENGINETURBOCHARGER SYSTEM (2JZ±GTE)

5. INSPECT EXHAUST BYPASS VALVE OPERATION
(a) Plug one side of the actuator air hose end.
(b) Using SST, apply approx. 98 kPa (1.00 kgf/cm
2, 14.2 psi) of
pressure to the actuator.
SST 09992±00241
(c) Move the actuator push rod, and check that the exhaust
bypass valve is open.
If operation is not as specified, replace the No.2 turbocharger
assembly.
NOTICE: Never apply more than 187 kPa (1.91 kgf/cm2, 27.2
psi) of pressure to the actuator.
(d) Remove the plug from the actuator air hose end.
Intake Air Control Valve
INSPECT CONTROL VALVE OPERATION
(a) Using SST, apply approx. 49 kPa (0.50 kgf/cm
2, 7.1 psi) of
pressure to the actuator.
SST 09992±00241
(b) Move the actuator push rod, and check that the control valve
is open.
If operation is not as specified, replace the control valve as-
sembly.
Exhaust Gas Control Valve
INSPECT CONTROL VALVE FOR DAMAGE
Move the actuator push rod and control valve, and check the
control valve for damage.
If the valve is damaged, replace the control valve assembly.
Air Bypass Valve
INSPECT AIR BYPASS VALVE OPERATION
(a) Check that air does not flow from port A to B.
(b) Apply vacuum to the actuator.
(c) Check that air flows from port A to B.
If operation is not as specified, replace the valve.
± ENGINETURBOCHARGER SYSTEM (2JZ±GTE)EG±159