TOYOTA SUPRA 1995 Service Repair Manual

Brushes
INSPECT EXPOSED BRUSH LENGTH
Using a vernier caliper, measure the exposed length.
Standard exposed length:
10.5 mm (0.413 in.)
Minimum exposed length:
1.5 mm (0.059 in.)
If the exposed length is less than minimum, replace the brush
holder.
Rectifiers (Rectifier Holder)
1. INSPECT POSITIVE RECTIFIER
(a) Using an ohmmeter, connect one tester probe to the positive
(+) terminal and the other to each rectifier terminal.
(b) Reverse the polarity of the tester probes and repeat step (a).
(c) Check that one shows continuity and the other shows no
continuity.If continuity is not as specified, replace the rectifier
holder.
2. INSPECT NEGATIVE RECTIFIER
(a) Using an ohmmeter, connect one tester probe to each
negative (±) terminal and the other to each rectifier terminal.
(b) Reverse the polarity of the tester probes and repeat step (a).
(c) Check that one shows continuity and the other shows no con-
tinuity.
If continuity is not as specified, replace the rectifier holder.
Bearings
1. INSPECT FRONT BEARING
Check that the bearing is not rough or worn.
± CHARGING SYSTEMGENERATORCH±14

2. IF NECESSARY. REPLACE FRONT BEARING
(a) Remove the 4 screws, bearing retainer and bearing.
(b) Using a socket wrench and press, press out the bearing.
(c) Using SST and a press, press in a new bearing.
SST 09608±20012 (09608±00030)
(d) Install the bearing retainer with the 4 screws.
3. INSPECT REAR BEARING
Check that the bearing is not rough or worn.
4. IF NECESSARY, REPLACE REAR BEARING
(a) Using SST, remove the bearing cover (outside) and bearing.
SST 09820±00021
NOTICE: Be careful not to damage the fan.
(b) Remove the beating cover (inside). CH±15
± CHARGING SYSTEMGENERATOR

(c) Place the bearing cover (inside) on the rotor.
(d) Using SST and a press, press in a new bearing.
SST 09820±00030
(e) Using SST, push in the bearing cover(outside).
SST 09285±76010
GENERATOR ASSEMBLY
1. PLACE RECTIFIER END FRAME ON PULLEY
2. INSTALL ROTOR TO RECTIFIER END FRAME
3. INSTALL RECTIFIER END FRAME
(a) Place the generator washer on the rotor.
± CHARGING SYSTEMGENERATORCH±16

(b) Using a 29 mm socket wrench and press, slowly press in the
rectifier end frame.
(c) Install the 3 nuts.
Torque: 4.5 NVm (46 kgfVcm, 40 in.Vlbf)
4. INSTALL PULLEY
(a) Install the pulley to the rotor shaft by tightening the pulley nut
by hand.
(b) Hold SST (A) with a torque wrench, and tighten SST (b)
clockwise to the specified torque.
SST 09820±63010
Torque: 39 NVm (400 kgfVcm, 29 ftVlbf)
(c) Check that SST (A) is secured to the pulley shaft.
(d) Mount SST (C) in a vise.
(e) Insert SST (B) into SST (C), and attach the pulley nut to SST
(C).
(f) To torque the pulley nut, turn SST (A) in the direction shown
in the illustration.
Torque: 110 NVm (1,125 kgfVcm, 81 ftVlbf)
(g) Remove the generator from SST (C). CH±17
± CHARGING SYSTEMGENERATOR

(h) Turn SST (B), and remove SST (A and B).
5. INSTALL RECTIFIER HOLDER
(a) Install the 4 rubber insulators on the lead wires.
(b) Install the rectifier holder while pushing it with the 4 screws.
Torque: 2.0 NVm (20 kgfVcm, 17 in.Vlbf)
6. INSTALL WIRE CLIP
Install the wire clip with the nut.
Torque: 4.5 NVm (46 kgfVcm, 40 in.Vlbf)
7. INSTALL VOLTAGE REGULATOR AND BRUSH HOLDER
(a) Place the seal plate on the rectifier end frame.
± CHARGING SYSTEMGENERATORCH±18

(b) Place the voltage regulator and brush holder on the rectifier
end frame.
NOTICE: Be careful of the holder installation direction.
(c) Install the 5 screws until there is a clearance of approx. 1 mm
(0.04 in.) between the brush Holder and voltage regulator.
(d) Place the brush holder cover on the brush holder.
8. INSTALL REAR END COVER
(a) Install the end cover and plate terminal with the bolt and 3
nuts.
Torque:
Nut
4.5 NVm (46 kgfVcm, 40 in.Vlbf)
Bolt
3.9 NVm (40 kgfVcm, 35 in.Vlbf)
(b) Install the terminal insulator with the nut.
Torque: 6.5 NVm (66 kgfVcm, 58 in.Vlbf)
9. CHECK THAT ROTOR ROTATES SMOOTHLY CH±19
± CHARGING SYSTEMGENERATOR

SERVICE SPECIFICATIONS
SERVICE DATA
 
 
 
Battery 
 
 
Voltage (Maintenance±free battery) at 205C (685F)
Specific gravity (Except maintenance±free battery)
at 205C(685F) 
 
 
12.7±12.9 V
1.27±1.29
 
 
 
 
 
 
Generator 
 
 
 
 
 
Rated output 2JZ±GE
2JZ±GTE
Rotor coil resistance at 205C (685C)
Slip ring diameter STD
Minimum
Brush exposed length STD
Minimum 
 
 
 
 
 
12 V 90 A
12 V 100 A
2.8±3.0

14.2±14.4 mm (0.559±0.567 in.)
12.8 mm (0.504 in.)
10.5 mm (0.413 in.)
1.5 mm (0.059 in.)
 
 Voltage
regulator 
 Regulating voltage at 255C (775F)
at 1155C (2395F) 
 13.6±14.8 V
13.2±14.0 V
TORQUE SPECIFICATIONS
 Part tightened NVm kgfVcm ftVlbf Rectifier end frame X Drive end frame 4.5 46 40 in.Vlbf 


Generator pulley X Rotor
 11 0 
 1,125 
 81
 Rectifier holder X Coil lead on rectifier end frame 2.0 20 17 in.Vlbf
 Rear end cover X Rectifier holder 4.5 46 40 in.Vlbf
 Plate terminal X Rectifier holder 3.9 40 35 in.Vlbf
 Terminal insulator X Rectifier holder 6.5 66 58 in.Vlbf
 Generator X Water pump 37 380 27
 Generator X Cylinder block 37 380 27
± CHARGING SYSTEMSERVICE SPECIFICATIONSCH±20

CLUTCH
CL±1

PREPARATION
SST (SPECIAL SERVICE TOOLS)
09023±00100 Union Nut Wrench 10 mm
09301±00110 Clutch Guide Tool
Clutch line
09303±35011 Input Shaft Front Bearing Puller
09304±30012 Input Shaft Front Bearing
Replacer
09333±00013 Clutch Diaphragm Spring Aligner
2JZ±GE Only
RECOMMENDED TOOLS
09082±00050 TOYOTA Electrical Tester Set
09905±00012Snap Ring No. 1 Expander
EQUIPMENT
 
  Calipers
 
 
  Dial indicator  Dial indicator
  To rque wrench  Torque wrench
CL±2± CLUTCHPREPARATION

TROUBLESHOOTING
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
CL±4CL±6CL±11See page
Parts Name
Trouble
Clutch grabs/chatters
Clutch noisy
Clutch slips
Clutch pedal spongy
Clutch does not disengage
Clutch pedal (freeplay out of adjustment)Pilot bearing (Worn or damaged)Release bearing (Worn, dirty or damaged)Engine mounting (loosen)Release cylinder cup (Damaged)master cylinder cup (Damaged)Clutch line (Air in line)Clutch disc (Dirty or burred)Clutch disc (Oily)Clutch disc (Worn out)Clutch disc torsion rubber (Damaged)Clutch disc (Out of true)Input shaft bearing (Worn or damaged)Clutch disc (Lining broken)Clutch disc (Runout is excessive)Clutch disc (Lack of spline grease)Diaphragm spring (Damaged)Clutch disc (Glazed)Diaphragm spring (Out of tip alignment)Pressure plate (Distortion)Flywheel (Distortion)
CL±17CL±8CL±9CL±11CL±17CL±11CL±17CL±11CL±17CL±11CL±17CL±11CL±17CL±11CL±17CL±11CL±17CL±11CL±17CL±11CL±17CL±15CL±21CL±11CL±17CL±15CL±20CL±11CL±17
± CLUTCHTROUBLESHOOTINGCL±3