TOYOTA SUPRA 1986 Service Repair Manual

PREPARATION FOR DISASSEMBLY
1. M/T:
REMOVE FLYWHEEL
2. A/T:
REMOVE DRIVE PLATE
3. INSTALL ENGINE TO ENGINE STAND FOR
DISASSEMBLY
4. REMOVE GENERATOR
5. REMOVE TIMING BELT AND PULLEYS
(See timing belt removal)
6. REMOVE CYLINDER HEAD
(See cylinder head removal)
7. REMOVE OIL FILTER
(See oil and filter replacement in Lubrication System)
8. 2JZ±GTE:
REMOVE OIL COOLER
(See oil cooler removal in Lubrication System)
9. REMOVE NO.2 WATER BYPASS PIPE
(a) 2JZ±GE:
Remove the bolt, 2 nuts, water bypass pipe and gasket.
(b) 2JZ±GTE:
Remove the 2 bolts, 2 nuts, water bypass pipe and gasket.
10. REMOVE OIL FILTER BRACKET
Remove the union bolt, gasket, oil filter bracket and O ±ring.
11. REMOVE LH ENGINE MOUNTING BRACKET AND
INSULATOR ASSEMBLY
12. REMOVE FUEL PIPE SUPPORT EG±98
± ENGINEENGINE MECHANICAL

13. REMOVE OIL PRESSURE SWITCH AND KNOCK
SENSORS
Using SST, remove the switch and sensors.
SST 09816±30010
14. 2JZ±GTE:
REMOVE UNION FOR OIL COOLER HOSE
15. REMOVE ENGINE COOLANT DRAIN PLUG
16. R E M O V E R H E N G I N E M O U N T I N G B R A C K E T A N D
INSULATOR ASSEMBLY
17. 2JZ±GTE:
REMOVE CRANKSHAFT POSITION SENSOR
18. REMOVE WATER PUMP
(See water pump removal in Cooling System)
19. REMOVE OIL PUMP
(See oil pump removal in Lubrication System)
CYLINDER BLOCK DISASSEMBLY
1. REMOVE REAR OIL SEAL RETAINER
(a) Remove the 6 bolts.
(b) Remove the oil seal retainer by prying the area between the
oil seal retainer and main bearing cap with a screwdriver.
2. CHECK CONNECTING ROD THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while
moving the connecting rods back and forth.
Standard thrust clearance:
0.250±0.402 mm (0.0098±0.0158 in.)
Maximum thrust clearance:
0.50 mm (0.0197 in.)
If the thrust clearance is greater than maximum, replace the
connecting rod assembly(s). If necessary, replace the crank-
shaft.
Connecting rod thickness:
25.898±25.950 mm (1.0196±1.0217 in.)
3. REMOVE CONNECTING ROD CAPS AND CHECK OIL
CLEARANCE
(a) Check the matchmarks on the connecting rod and cap to
ensure correct reassembly.
± ENGINEENGINE MECHANICALEG±99

(b) Remove the connecting rod cap bolts.
(c) Using the 2 removed connecting rod bolts, remove the
connecting rod cap and lower bearing by wiggling the
connecting rod cap right and left.
HINT: Keep the lower bearing inserted with the connecting
rod cap.
(d) Clean the crank pin and bearings.
(e) Check the crank pin and bearing for pitting and scratches.
If the crank pin or bearing is damaged, replace the bearings.
If necessary, replace the crankshaft.
(f) Lay a strip of Plastigage across the crank pin.
(g) Install the connecting rod cap with the 2 bolts.
(See step 8 in cylinder block assembly)
Torque:
1st
29 NVm (300 kgfVcm, 22 ftVlbf)
2nd
Turn 905
NOTICE: Do not turn the crankshaft.
(h) Remove the 2 bolts, connecting rod cap and lower bearing.
(See procedure (b) and (c) above) EG±100
± ENGINEENGINE MECHANICAL

(i) Measure the Plastigage at its widest point.
Standard oil clearance:
STD
.035±0.053 mm (0.0014±0.0021 in.)
U/S 0.25
.040±0.078 mm (0.0016±0.0031 in.)
Maximum oil clearance.
STD
.08 mm (0.0031 in.)
U/S 0.25
.09 mm (0.0035 in.)
If the oil clearance is greater than maximum, replace the
bearings. If necessary, grind or replace the crankshaft.
HINT: If using a standard bearing, replace with one having
the same number. If the number of the bearing cannot be de-
termined, select the correct bearing by adding together the
numbers imprinted on the connecting rod cap and crank-
shaft, then selecting the bearing with the same number as the
total. There are 5 sizes of standard bearings, marked º1º, º2º,
º3º, º4º and º5º accordingly.
  Number mark
 Connecting rod cap 1 2 3 
 Crankshaft
 

0
 
 1
 

2
 
 0
 
 1
 

2
 
 0
 

1
 
 2
 Use bearing 1 2 3 2 3 4 3 4 5
EXAMPLE: Connecting rod cap º3º +Crankshaft º1º = Total
number 4 (Use bearing º4º)
Reference:
Connecting rod big end inside diameter:
Mark º1º
55.025±55.031 mm (2.1663±2.1666 in.)
Mark º2º
55.031±55.037 mm (2.1666±2.1668 in.)
Mark º3º
55.037±55.043 mm (2.1668±2.1670 in.)
Crankshaft crank pin diameter:
Mark º0º
51.994±52.000 mm (2.0470±2.0472 in.)
Mark º1º
51.988±51.994 mm (2.0468±2.0470 in.)
Mark º2º
51.982±51.988 mm (2.0465±2.0468 in.)
± ENGINEENGINE MECHANICALEG±101

Bearing center wall thickness:
Mark º1º
1.492±1.495 mm (0.0587±0.0589 in.)
Mark º2º
1.495±1.498 mm (0.0589±0.0590 in.)
Mark º3º
1.498±1.501 mm (0.0590±0.0591 in.)
Mark º4º
1.501±1.504 mm (0.0591±0.0592 in.)
Mark º5º
1.504±1.507 mm (0.0592±0.0593 in.)
(j) Completely remove the Plastigage.
4. REMOVE PISTON AND CONNECTING ROD
ASSEMBLIES
(a) Using a ridge reamer, remove all the carbon from the top of
the cylinder.
(b) Push the piston, connecting rod assembly and upper bearing
through the top of the cylinder block.
HINT:
wKeep the bearings, connecting rod and cap together.
wArrange the piston and connecting rod assemblies in
correct order.
5. CHECK CRANKSHAFT THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while pry-
ing the crankshaft back and forth with a screwdriver.
Standard thrust clearance:
0.020±0.220 mm (0.0008±0.0087 in.)
Maximum thrust clearance:
0.30 mm (0.0118 in.)
If the thrust clearance is greater than maximum, replace the
thrust washers as a set.
Thrust washer thickness:
1.940±1.990 mm (0.0764±0.0783 in.)
6. REMOVE MAIN BEARING CAPS AND CHECK OIL
CLEARANCE
(a) Uniformly loosen and remove the 14 main bearing cap bolts,
in severval passes, in the sequence shown.
(b) Using the removed main bearing cap bolts, pry the main
bearing cap back and forth, and remove the main bearing
caps, lower bearings and lower thrust washers (No.4 main
bearing cap only).
HINT:
wKeep the lower bearing and main bearing cap together.
wArrange the main bearing caps and lower thrust
washers in correct order. EG±102
± ENGINEENGINE MECHANICAL

(c) Lift out the crankshaft.
HINT: Keep the upper bearing and upper thrust washers to-
gether with the cylinder block.
(d) Clean each main journal and bearing.
(e) Ch e ck ea ch ma in jo u rn a l an d be a rin g fo r pittin g an d
scratches.
If the journal or bearing is damaged, replace the bearings. If
necessary, grind or replace the crankshaft.
(f) Place the crankshaft on the cylinder block.
(g) Lay a strip of Plastigage across each journal.
(h) Install the main bearing caps.
(See step 5 in cylinder block installation)
Torque:
1st
44 NVm (450 kgfVcm, 33 ftVlbf)
2nd
Turn 90°
NOTICE: Do not turn the crankshaft.
(i) Remove the main bearing caps.
(See procedures (a) and (b) above)
(j) Measure the Plastigage at its widest point.
Standard clearance:
STD
.026±0.040 mm (0.0010±0.0016 in.)
U/S 0.25
.025±0.061 mm (0.0010±0.0024 in.)
Maximum clearance:
STD
.06 mm (0.0024 in.)
U/S 0.25
.08 mm (0.0031 in.)
If the oil clearance is greater than maximum, replace the
bearings. If necessary, grind or replace the crankshaft.
± ENGINEENGINE MECHANICALEG±103

HINT: If using a standard bearing, replace with one having
the same number. If the number of the bearing cannot be de-
termined, select the correct bearing by adding together the
numbers imprinted on the cylinder block and crankshaft, then
refer to the table below for the appropriate bearing number.
There are 5 sizes of standard bearings, marked º1º, º2º, º3º,
º4º and º5º accordingly.
 
 
 
 Total number º º:Number mark
 Cylinder block (A)
+
 
02
 
35
 
68
 
911
 
12 14 
 
+
Crankshaft (B) = 
 
0±2 
 
3±5 
 
6±8 
 
9±11 
 
12±14
 Use bearingº1ºº2ºº3ºº4ºº5ºUse bearingº1ºº2ºº3ºº4ºº5º
EXAMPLE: Cylinder block º3º (A)
+ Crankshaft º4º(B)
= Total number 7 (Use bearing º3º)
Reference:
Cylinder block main journal bore diameter (A):
Mark º0º
66.020±66.022 mm (2.59922±2.59929 in.)
Mark º1º
66.022±66.024 mm (2.59929±2.59936 in.)
Mark º2º
66.024±66.026 mm (2.59936±2.59944 in.)
Mark º3º
66.026±66.028 mm (2.59944±2.59952 in.)
Mark º4º
66.028±66.030 mm (2.59952±2.59960 in.)
Mark º5º
66.030±66.032 mm (2.59960±2.59968 in.)
Mark º6º
66.032±66.034 mm (2.59968±2.59976 in.)
Mark º7º
66.034±66.036 mm (2.59976±2.59984 in.)
Crankshaft main journal diameter (B):
Mark º0º
61.998±62.000 mm (2.44086±2.44094 in.)
Mark º1º
61.996±61.998 mm (2.44078±2.44086 in.)
Mark º2º
61.994±61.996 mm (2.44070±2.44078 in.)
Mark º3º
61.992±61.994 mm (2.44063±2.44070 in.)
Mark º4º
61.990±61.992 mm (2.44055±2.44063 in.)
Mark º5º
61.988±61.990 mm (2.44047±2.44055 in.) EG±104
± ENGINEENGINE MECHANICAL

Mark º6º
61.986±61.988 mm (2.44039±2.44047 in.)
Mark º7º
61.984±61.986 mm (2.44031±2.44039 in.)
Bearing center wall thickness:
Mark º1º
1.994±1.997 mm (0.0785±0.0786 in.)
Mark º2º
1.997±2.000 mm (0.0786±0.0787 in.)
Mark º3º
2.000±2.003 mm (0.0787±0.0789 in.)
Mark º4º
2.003±2.006 mm (0.0789±0.0790 in.)
Mark º5º
2.006±2.009 mm (0.0790±0.0791 in.)
Standard sized Bearing Selection chart
 Crankshaft Cylinder block number mark
 number mark 0 1 2 3 4 5 6 7
011122233 011122233
 111222333

111222333
 212223334212223334 322233344322233344 422333444 422333444
523334455 523334455
633344555 633344555
733445555 733445555
EXAMPLE: Cylinder block º3º Crankshaft º4º
= Use bearing º3º
(k) Completely remove the Plastigage.
7. REMOVE CRANKSHAFT
(a) Lift out the crankshaft
(b) Remove the upper bearings and upper thrust washers from
the cylinder block.
HINT: Arrange the main bearing caps, bearings and thrust
washers in the correct order.
8. 2JZ±GTE:
REMOVE OIL NOZZLES (WITH RELIEF VALVES)
Using a 5 mm hexagon wrench, remove the bolt and oil
nozzle. Remove the 6 oil nozzles.
± ENGINEENGINE MECHANICALEG±105

CYLINDER BLOCK INSPECTION
1. CLEAN CYLINDER BLOCK
A. Remove gasket material
Using a gasket scraper, remove all the gasket material from
the cylinder block surface.
B. Clean cylinder block
Using a soft brush and solvent, thoroughly clean the cylinder
block.
2. INSPECT CYLINDER BLOCK SURFACE FOR FLATNESS
Using precision straight edge and feeler gauge, measure the
surfaces of the cylinder block for warpage.
Maximum warpage:
0.07 mm (0.0028 in.)
If warpage is greater than maximum, replace the cylinder
block.
3. INSPECT CYLINDER FOR VERTICAL SCRATCHES
Visually check the cylinder for vertical scratches.
If deep scratches are present, replace the cylinder block.
4. INSPECT CYLINDER BORE DIAMETER
Using a cylinder gauge, measure the cylinder bore diameter
at positions A, B and C in the thrust and axial directions.
Standard diameter:
86.000±86.013 mm (3.3858±3.3863 in.)
Maximum diameter:
86.02 mm (3.3866 in.)
If the diameter is greater than maximum, replace the cylinder
block. EG±106
± ENGINEENGINE MECHANICAL

5. REMOVE CYLINDER RIDGE
If the wear is less than 0.2 mm (0.008 in.), using a ridge ream-
er, grind the top of the cylinder.
6. INSPECT MAIN BEARING CAP BOLTS
Using vernier calipers, measure the minimum diameter of the
compressed thread at the measuring point.
Standard diameter:
9.96±9.97 mm (0.3921±0.3925 in.)
Minimum diameter:
9.7 mm (0.382 in.)
If the diameter is less than minimum, replace the bolt.
PISTON AND CONNECTING ROD
DISASSEMBLY
1. CHECK FIT BETWEEN PISTON AND PISTON PIN
Try to move the piston back and forth on the piston pin.
If any movement is felt, replace the piston and pin as a set.
2. REMOVE PISTON RINGS
(a) Using a piston ring expander, remove the 2 compression
rings.
(b) Remove the 2 side rails and oil ring expander by hand.
HINT: Arrange the piston rings in correct order only.
3. DISCONNECT CONNECTING ROD FROM PISTON
(a) Using a small screwdriver, remove the 2 snap rings.
± ENGINEENGINE MECHANICALEG±107