TOYOTA SUPRA 1997 Service User Guide

Q04326
Matchmarks
Secondary
FlywheelPrimary
Flywheel
Q04327
Matchmarks CL-24
- CLUTCHCLUTCH UNIT (2JZ-GTE)
1565 Author
: Date
:
1997 SUPRA (RM502U)
8. INSPECT FLYWHEEL DAMPER FOR GREASE LEAK-
AGE
If grease has sprayed onto the clutch housing, replace the fly-
wheel assembly.
9. INSPECT FLYWHEEL DAMPER ROTATIONAL FREE-
PLAY
(a) Install the 2 bolts to the secondary flywheel at diametrical-
ly opposite positions.
(b) Holding both the bolts, and turn the secondary flywheel
clockwise until it stops.
(c) Put matchmarks on the primary and secondary flywheels
at this position.
(d) Then rotate the primary flywheel counterclockwise by
hand until it stops.
(e) Put matchmarks on the primary flywheel at this position.
(f) Measure the circumferential length between the 2 match-
marks on the secondary flywheel.
Standard: 105 mm (4.134 in.)
(g) Repeat the previous steps (d) to (f) 4 times and if the mea-
surement is greater than the maximum length replace the
flywheel assembly (See page EM-88).

CL04D-01
Z13786
SST Front
Q04210
SST 7
3
1, 4
2, 58 6 Matchmarks
Q06263
SST
Q04219
Q04403
- CLUTCHCLUTCH UNIT (2JZ-GTE)
CL-25
1566 Author
: Date
:
1997 SUPRA (RM502U)
INSTALLATION
1. INSTALL CLUTCH DISC AND COVER ON FLYWHEEL
(a) Insert SST in the clutch disc, then set them and the cover
in position.
SST 09301-001 10
(b) Align the matchmarks on the clutch cover and flywheel.
(c) Tighten the bolts evenly and gradually while pushing the
SST. Make several passes around the cover until it is
snug.
(d) Torque the bolts on the clutch cover in the order shown.
Torque: 19 N´m (195 kgf´cm, 14 ft´lbf)
HINT:
Temporarily tighten the No.1 and No.2 bolts.
2. CHECK DIAPHRAGM SPRING TIP ALIGNMENT
Using a dial indicator with roller instrument, check the dia-
phragm spring tip alignment.
Maximum non-alignment: 0.5 mm (0.020 in.)
If the alignment is not as specified, use SST to adjust the dia-
phragm spring tip alignment.
SST 09333-00013
3. REMOVE CLUTCH COVER AND CLUTCH DISC
4. INSTALL CLUTCH RELEASE FORK
(a) Install the wave washer and pin to release fork.
(b) Install a new E-ring.
5. APPLY MOLYBDENUM DISULPHIDE LITHIUM BASE
GREASE (NLGI NO.2)
(a) Apply release hub grease to these parts:

Release fork and hub contact point

Release fork and push rod contact point

Release fork pivot point

Q04325
Q04218
Q04213
Snap Ring
Wave Washer
Plate Washer
Q04222
Q04215
Snap Ring CL-26
- CLUTCHCLUTCH UNIT (2JZ-GTE)
1567 Author
: Date
:
1997 SUPRA (RM502U)

Release bearing hub inside groove

Release bearing front surface
(b) Apply clutch spline grease.

Clutch disc spline
HINT:
Recommended grease part number 08887-01706 (100 g).
6. INSTALL CLUTCH RELEASE BEARING
(a) Install the release bearing hub, wave washer and plate
washer.
(b) Using a snap ring expander, install a new snap ring.
7. INSTALL CLUTCH RELEASE BEARING HUB
(a) Install the thrust cone washer and plate washer to release
bearing hub.
NOTICE:
Install the thrust cone washer in the correct direction.
(b) Install the release bearing hub to release bearing.
(c) Using a snap ring expander, install a new snap ring.

Q04216
Front
Q04195
- CLUTCHCLUTCH UNIT (2JZ-GTE)
CL-27
1568 Author
: Date
:
1997 SUPRA (RM502U)
8. INSTALL CLUTCH COVER ASSEMBLY
9. INSTALL CLUTCH DISC
NOTICE:
Install the clutch disc in the correct direction.
10. INSTALL RELEASE FORK ASSEMBLY
Install the release bearing assembly to the release fork assem-
bly, and install them to the transmission.
11. INSTALL TRANSMISSION TO ENGINE
(See page MT-2)

Q04160
Push Rod Play and
Freeplay Adjust Point
Pedal
HeightPedal Height
Adjust Point
Push Rod PlayCL03Z-01
CL0102Pedal Freeplay
Z13785
25 mm (0.98 in.) or more
Full Pedal Stroke Full Stroke
End PositionRelease
Point
- CLUTCHCLUTCH PEDAL
CL-3
1544 Author
: Date
:
1997 SUPRA (RM502U)
CLUTCH PEDAL
INSPECTION
1. CHECK PEDAL HEIGHT
Pedal height from asphalt sheet:
146.2 - 156.2 mm (5.76 - 6.15 in.)
2. IF NECESSARY, ADJUST PEDAL HEIGHT
Loosen the lock nut and clutch switch until the height is correct.
Tighten the lock nut.
HINT:
Before rotating the clutch switch for pedal height adjustment,
disconnect the clutch switch connector.
3. CHECK PEDAL FREEPLAY AND PUSH ROD PLAY
Push in on the pedal until the beginning of clutch resistance is
felt.
Pedal freeplay: 5.0 - 15.0 mm (0.197 - 0.591 in.)
Gently push on the pedal until the resistance begins to increase
a little.
Push rod play at pedal top:
1.0 - 5.0 mm (0.039 - 0.197 in.)
4. IF NECESSARY, ADJUST PEDAL FREEPLAY AND
PUSH ROD PLAY
(a) Loosen the lock nut and turn the push rod until the free-
play and push rod play are correct.
(b) Tighten the lock nut.
(c) After adjusting the pedal freeplay, check the pedal height.
5. INSPECT FULL PEDAL STROKE
Full pedal stroke: 132.0 - 138.0 mm (5.20 - 5.43 in.)
6. INSPECT CLUTCH RELEASE POINT
(a) Pull the parking brake lever and install wheel stopper.
(b) Start the engine and idle the engine.
(c) Without depressing the clutch pedal, slowly shift the shift
lever into the reverse position until the gears contact.
(d) Gradually depress the clutch pedal and measure the
stroke distance from the point the gear noise stops (re-
lease point) up to the full stroke end position.

Q04185
Clutch Start Switch
Q00617
8 ± 0.5 mm
(0.31 ± 0.020 in.) CL-4
- CLUTCHCLUTCH PEDAL
1545 Author
: Date
:
1997 SUPRA (RM502U)
Standard distance: 25 mm (0.98 in.) or more
(From pedal stroke end position to release point)
If the distance is not as specified, do the following operation.

Inspect pedal height.

Inspect push rod play and pedal freeplay.

Bleed the clutch line.

Inspect the clutch cover and disc.
7. CHECK CLUTCH START SYSTEM
(a) Check that the engine does not start when the clutch ped-
al is released.
(b) Check that the engine starts when the clutch pedal is fully
depressed.
If necessary, adjust or replace the clutch start switch.
8. INSPECT CONTINUITY OF CLUTCH START SWITCH
(a) Check that there is continuity between the terminals when
the switch is ON (pushed).
(b) Check that there is no continuity between the terminals
when the switch is OFF (free).
If continuity is not as specified, replace the switch.

CL040-01
Z16903
Filler Cap
Reservoir Tank
Slotted Spring
Pin
Clutch Line
Push Rod
Grommet Float
Clip Pin
Clevis
Boot
Washer

Snap Ring
Lock Nut15 (155, 11)
12 (125, 9)
12 (125, 9)
N´m (kgf´cm, ft´lbf)
: Specified torque

Non-reusable partPiston
Master Cylinder Body
- CLUTCHCLUTCH MASTER CYLINDER
CL-5
1546 Author
: Date
:
1997 SUPRA (RM502U)
CLUTCH MASTER CYLINDER
COMPONENTS

CL041-01
Q04188SST CL-6
- CLUTCHCLUTCH MASTER CYLINDER
1547 Author
: Date
:
1997 SUPRA (RM502U)
REMOVAL
1. DRAIN OUT FLUID WITH SYRINGE
2. DISCONNECT CLUTCH LINE UNION
Using SST, disconnect the union nut.
SST 09023-00100
Torque: 15 N´m (155 kgf´cm, 11 ft´lbf)
3. REMOVE CLIP AND PIN
4. REMOVE 2 MOUNTING NUTS AND PULL OUT MAS-
TER CYLINDER
Torque: 12 N´m (125 kgf´cm, 9 ft´lbf)

CL042-01
Q04189
Q04190
- CLUTCHCLUTCH MASTER CYLINDER
CL-7
1548 Author
: Date
:
1997 SUPRA (RM502U)
DISASSEMBLY
1. REMOVE RESERVOIR TANK
(a) Using a pin punch and hammer, drive out the slotted
spring pin.
(b) Remove the reservoir tank and grommet.
2. REMOVE PUSH ROD
(a) Pull back the boot, and using snap ring pliers, remove the
snap ring.
(b) Pull out the push rod.
3. REMOVE PISTON

CL044-01
Z08053
Q04313
Protrusion
1.5 - 3.5 mm
(0.059 - 0.138 in.) CL-8
- CLUTCHCLUTCH MASTER CYLINDER
1549 Author
: Date
:
1997 SUPRA (RM502U)
REASSEMBLY
1. COAT PARTS WITH LITHIUM SOAP BASE GLYCOL
GREASE, AS SHOWN
2. INSERT PISTON INTO CYLINDER
3. INSTALL PUSH ROD ASSEMBLY WITH NEW SNAP
RING
4. INSTALL RESERVOIR TANK
(a) Install the reservoir tank and a new grommet.
(b) Using a pin punch and hammer, drive in the slotted spring
pin.