TOYOTA SUPRA 1997 Service Repair Manual

mm in.
50.20Normal Roof:
Sport Roof:
1. Before temporarily installing the new parts, apply
body sealer to the wheel arch.
HINT:1) Apply body sealer about 5 mm (0.20 in.) from the
flange, avoiding any oozing.
2) Apply sealer evenly, about 3 - 4 mm (0.12 - 0.16
in.) in diameter.
3) For other sealing points, refer to section AR.BODY PANEL REPLACEMENT
RE-36
INSTALLATION
Butt Weld
Butt Weld
Body Sealer
Butt Weld
Body Sealer
about 5 mm
2. Temporarily install the new parts and check the fit of
the front door, back door and rear combination lamp.
3. Apply foamed material to the pillar section.HINT: For the foamed material application areas, refer to
page AP-4.
INSTALLATION DIAGRAM
Describes in detail installation of the new parts involving repair by welding and/or cutting, but
excluding painting.
INSTALLATION GUIDE
Provides additional information to more efficiently help you perform the installation.
SYMBOLS
See page IN-4.
ILLUSTRATION OF WELD POINTS
Weld method and panel position symbols.
See page IN-5.
INTRODUCTIONIN-3

SYMBOLSMEANINGILLUSTRATION
SAW CUT OR
ROUGH CUT
REMOVE BRAZE
(See page IN-5) SPOT WELD OR
MIG PLUG WELD WELD POINTS
BRAZE CONTINUOUS MIG
WELD (BUTT WELD
OR TACK WELD)
BODY SEALER
SYMBOLS
The following symbols are used in the welding Diagrams in Section RE of this manual to indicate cutting
areas and the types of weld required.
INTRODUCTIONIN-4

Remove weld point and panel positionWeld points
REMOVAL
Weld method and panel positionWeld points
INSTALLATION
SYMBOL MEANING ILLUSTRATIONSYMBOL
Spot WeldMEANINGILLUSTRATION
Remove
Weld
Points
(Outside)
Mig Plug
Weld
(Middle)
(Inside)
Spot MIG
Weld
HINT: Panel position syrnbols are as seen from the
working posture.
Illustration of Weld Point Symbols
EXAMPLE:
INTRODUCTIONIN-5

Steering Wheel Pad
(with Airbag) Junction Block No. 1Center Airbag Sensor Assembly Front Airbag Sensor LHFront Passenger Airbag Assembly Front Airbag Sensor RHSRS Warning Light
Spiral Cable
Locations of SRS Components
HANDLING PRECAUTIONS ON RELATED COMPONENTS
1. SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Servicing vehicle with a Supplemental Restraint System (referrerd to as the SRS in the remainder of this
manual) installed.
When handling SRS components (removal, installation or inspection, etc.), always follow the directions
given in the repair manual for the relevant model year to prevent the occurrence of accidents and airbag
malfunction.
Also take the following precautions when repairing the body:

Work must be started after 90 seconds or longer from the time the ignition switch is set to the LOCK
position and the negative (-) terminal cable is disconnected from the battery.
(The airbag system is equipped with a backup power source so that if work is started within 20 seconds
of disconnecting the negative (-) terminal cable of the battery, the airbag may be deployed.)
When the negative (-) terminal cable is disconnected from the battery, memory of the clock and audio
systems will be cancelled. So before starting work, make a record of the contents memorized by each
memory system. Then when work is finished, reset the clock and audio systems as before.
When the vehicle has tilt and telescopic steering, power seat, outside rear view mirror and power shoul-
der belt anchorage, which are all equipped with memory function, it is not possible to make a record of
the memory contents. So when the operation is finished, it will be necessary to explain this fact to the
customer, and request the customer to adjust the features and reset the memory.

When using electric welding, first disconnect the SRS connector (yellow color and 2 pins) under the
steering column near the combination switch connector on the glove compartment finish plate and lower
the front scuff plate before starting work.
INTRODUCTIONIN-6

Front Fender Area

Before repairing the body, remove the SRS parts if, during repair, shocks are likely to be applied to
the sensors due to vibrations of the body or direct tapping with tools or other parts.

Do not expose the SRS parts directly to hot air or flames.
NOTICE:
1) The maximum ambient temperature tolerance is 120
°C (248°F) for the front airbag sensor,
105
°C (221°F) for the center airbag sensor assembly and 93°C (200°F) for the steering wheel
pad, and front passenger airbag assembly. If it is possible that the ambient temperature may
reach or exceed the temperature limit, remove the sensors and the steering wheel pad from
the vihicle or protect them with a hot insulation material before starting work.
2) Prior to welding, remove adjacent SRS parts from the vehicle or protect there with fire-proof
covers.

If the front fender or periphery of the vehicle is damaged, visually inspect for damage to the front
airbag sensor using the inspection procedures described in section RS of the repair manual for the
relevant model year.
Also check that the dimensions of the body where the front airbag sensor is installed match those
in the body dimension drawings.
(The airbag may malfunction, or may not work, if the mounting angle or dimensions of the sensor
mount are not correct.)

If the vehicle is damaged, visually inspect for damage to the steering wheel pad using the inspection
procedures described in section RS of the repair manual for the relevant model year.

When removing or handling the steering wheel pad, and front passenger airbag assembly keep the
pad upper surface facing upward. Also, lock the lock lever of the twin lock type connector at the rear
of the pad and take care not to damage the connector.
(Storing the pad or front passenger airbag assembly with its metalic surface up may lead to a serious
accident if the airbag inflates for some reason.)

Store the steering wheel pad and the front passenger airbag assembly where the ambient tempera-
ture remains below 93°C (200°F), without high humidity and away from electrical noise.

Be careful not to let painting materials contact the SRS parts.

Information labels are attached to the periphery of the SRS components. Follow the NOTICES.

Store the airbag assembly where the ambient temperature remains below 93°C (200°F), without high
humidity and away from electrical noise.
INTRODUCTIONIN-7

Shift Lock ECUEngine Control
Module
(Engine ECU)Center Airbag
Sensor Assembly ABS
Deceleration
Sensor ABS and Traction ECU
(for 2JZ-GTE)Stereo Power
Amplifier Integration
RelayJ/B No. 1Traction ECU
(for 2JZ-GTE)
R/B No. 4 Daytime Running
Light Relay (Main)
(for Canada)Blower Control
RelayPPS ECU A/C AmplifierTheft Deterrent
ECU Cruise Control ECU Auto Antenna Control Relay
ABS ECU
(for 2JZ-GE)
Component to be alignedSection of repair manual
for relevant model year
Front Wheels
Suspension and Axle (SA) section
Rear Wheels
Suspension and Axle (SA) section
Propeller Shaft
Propeller Shaft (PR) section
3. DRIVE TRAIN AND CHASSIS2. BRAKE SYSTEM
The brake system is one of the most important safety components. Always follow the directions and
notes given in section BR of the repair manual for the relevant model year when handling brake
system parts.
NOTICE: When repairing the brake master cylinder or TRAC system, bleed the air out of the TRAC
system.
The drive train and chassis are components-that can have great effects on the running performance
and vibration resistance of the vehicle. After installing components in the sections listed in the table
below, perform alignments to ensure correct mounting angles and dimensions. Particularly accurate
repair of the body must also be done to ensure correct alignment.
HINT: Correct procedures and special tools are required for alignment. Always follow the directions
given in the repair manual for the relevant model year during alignment and section DI of this manual.
4. ECU (ELECTRONIC CONTROL UNIT)
Locations of ECUs
INTRODUCTIONIN-8

Light Failure Sensor Fuel Pump ECURear Wiper Relay
5. COMPONENTS ADJACENT TO THE BODY PANELS Locations of ECUs (Cont'd)
Many ECUs are mounted in this vehicle.
Take the following precautions during body repair to prevent damage to the ECUs.

Before starting electric welding operations, disconnect the negative (-) terminal cable from the battery.
When the negative (-) terminal cable is disconnected from the battery, memory of the clock and audio
systems will be cancelled. So before starting work, make a record of the contents memorized by each
memory system. Then when work is finished, reset the clock and audio systems as before.
When the vehicle has tilt and telescopic steering, power seat and outside rear view mirror, which are all
equipped with memory function, it is not possible to make a record of the memory contents.
So when the operation is finished, it will be necessary to explain this fact to the customer, and request
the customer to adjust the features and reset the memory.

Do not expose the ECUs to ambient temperatures above 80°C (176°F).
NOTICE: if it is possible the ambient temperature may reach 80°C (176°F) or more, remove the ECUs
from the vehicle before starting work.

Be careful not to drop the ECUs and not to apply physical shocks to them.
Various types of component parts are mounted directly on or adjacently to the body panels.
Strictly observe the following precautions to prevent damaging these components and the body panels
during handling.

Before repairing the body panels, remove their components or apply protective covers over the
components.

Before prying components off using screwdriver or a scraper, etc., attach protective tape to the tool
tip or blade to prevent damaging the components an the body paint.

Before removing components from the outer surface of the body, attach protective tape to the body
to ensure no damage to painted areas.
HINT: Apply touch-up paint to any damaged paint surfaces.

Before drilling or cutting sections, make sure that there are no wires, etc. on the reverse side.
INTRODUCTIONIN-9

GENERAL REPAIR INSTRUCTIONS
Work Precautions
VEHICLE PROTECTION
When welding, protect the
painted surfaces, windows,
seats an carpet with heat-
resistant, fire-proof covers.SAFETY
1. Before performing repair work, check
for fuel leaks. If a leak is found, be
sure to close the opening totally.
2. If it is necessary to use a frame in the
area of the-fuel tank, first remove the
tank and plug the fuel line. SAFETY
Never stand in direct line
with the chain when using
a puller on the body or
frame, and be sure to
attach a safety cable.
WRONG
Glass Cover
Safety Cable
Seat Cover
WRONG
HAND TOOLS
keeping your hand tools
in neat order improve
your work efficiency. SAFETY WORK CLOTHES
In addition to the usual mechanic's wear, cap and safety shoes,
the appropriate gloves, head protector, glasses, ear plugs, face
protector, dust-prevention mask, etc. should be worn as the
situation demands.
Dust-
Prevention
Mask.Welder's
Glasses
Ear
Plugs
Body
Mechanic
Stand Face
Protector
Head
Protector
Eye
Protector
Welder's
Gloves Safety
Shoes
INTRODUCTIONIN-10

Proper and Efficient Work Procedures
REMOVAL
NUMBER OF SPOT WELDS AND PANEL POSITIONS
The number of spot welds and the panel positions to be
removed are shown for your reference.
HINT: See ºSymbolsº on page IN-4, 5.
PRE-REMOV AL MEASURING
Before removal or cutting
operations, take measurements
in accordance with the dimension
diagram. Always use a puller to
straighten a damaged body or
frame.
REMOVAL OF ADJACENT COMPONENTS
When removing adjacent components, apply
protective tape to the surrounding body and
your tools to prevent damage.
HINT: See ºHandling Precautions on Related
Componentsº on age IN-6.
PRECAUTIONS FOR DRILLING OR
CUTTING
Check behind any area to be drilled or
cut to insure that there are no hoses,
wires, etc., that may be damaged.
HINT: See ºHandling Precautions on
Related Componentsº on page IN-6.
CUTTING AREA
Always cut in a straight
line and avoid reinforced
area.
Cutting Okay
Corners
Reinforcement
WRONG
INTRODUCTIONIN-11

Thickness of
welded portionSize of plug hole
1.0 (0.04) under5 (0.20)
f over
1.0 (0.04) - 1.5 (0.06)6.5 (0.26)
f over
1.5 (0.06) over8 (0.31)
f over
REFERENCE:mm (in.)
PREPARATION FOR INSTALLATION
APPLICATION OF WELD-THROUGH PRIMER
(SPOT SEALER) SPOT WELD POINTS
When welding panels with a
combined thickness of over
3 mm (0.12 in.), use a MIG
(Metal Inert Gas) welder for
plug welding.
HINT: spot welding will not
provide sufficient durability
for panels over 3 mm (0.12
in.) thick.
Remove the paint
from the portion of the
new parts and body to
be welded, and apply
weld-through primer.
HINT: See ºANTI-
RUST TREATMENTº
on page AR-2.
Less than
3 mm
Air Saw
WRONG
Puncher
20 - 30 mm
Overlap
ROUGH CUTTING OF JOINTS
For joint areas, rough cut the
new parts, leaving 20 - 30 mm
(0.79 - 1.18 in.) overlap.MAKING HOLES FOR PLUG WELDING
For areas where a spot welder cannot be
used, use a puncher or drill to make holes
for plug welding.
INTRODUCTIONIN-12