TOYOTA SUPRA 1997 Service Repair Manual

EM0AP-02
P02289
Z02380
P02286
Z00145
121
2 1Thrust
Direction
Axial
Direction
10 mm
(0.39 in)
10 mm
(0.39 in) Middle A
B
C Front
- ENGINE MECHANICAL (2JZ-GTE)CYLINDER BLOCK
EM-79
1184 Author
: Date
:
1997 SUPRA (RM502U)
INSPECTION
1. REMOVE GASKET MATERIAL
Using a gasket scraper, remove all the gasket material from the
cylinder block surface.
2. CLEAN CYLINDER BLOCK
Using a soft brush and solvent, thoroughly clean the cylinder
block.
3. 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.
4. INSPECT CYLINDER FOR VERTICAL SCRATCHES
Visually check the cylinder for vertical scratches.
If deep scratches are present, replace the cylinder block.
5. 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.

P02288
A02827
About
50 mm
Compressed
Thread
P02085
P02084
P02176
34 mm EM-80
- ENGINE MECHANICAL (2JZ-GTE)CYLINDER BLOCK
1185 Author
: Date
:
1997 SUPRA (RM502U)
6. REMOVE CYLINDER RIDGE
If the wear is less than 0.2 mm (0.008 in.), using a ridge reamer,
grind the top of the cylinder.
7. 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.
8. CLEAN PISTON
(a) Using a gasket scraper, remove the carbon from the pis-
ton top.
(b) Using a groove cleaning tool or broken ring, clean the pis-
ton ring grooves.
(c) Using solvent and a brush, thoroughly clean the piston.
NOTICE:
Do not use a wire brush.
9. INSPECT PISTON OIL CLEARANCE
(a) Using a micrometer, measure the piston diameter at right
angles to the piston pin center line, 34 mm (1.34 in.) from
the piston head.
Piston diameter:
85.917 - 85.927 mm (3.3826 - 3.3830 in.)

P02086
Z09736
105 mm
EM7639
Piston ringSTD mm (in.)
Maximum mm (in.)
No.1
No.2
Oil (Side rail)0.300 - 0.400
(0.0118 - 0.0157)
0.350 - 0.450
(0.0138 - 0.0178)
0.130 - 0.380
(0.0051 - 0.0150)1.000 (0.0394)
1.050 (0.0413)
0.980 (0.0386)
- ENGINE MECHANICAL (2JZ-GTE)CYLINDER BLOCK
EM-81
1186 Author
: Date
:
1997 SUPRA (RM502U)
(b) Measure the cylinder bore diameter in the thrust direc-
tions. (See step 5)
(c) Subtract the piston diameter measurement from the cylin-
der bore diameter measurement.
Standard oil clearance:
0.073 - 0.096 mm (0.0029 - 0.0038 in.)
Maximum oil clearance:
0.12 mm (0.0047 in.)
If the oil clearance is greater than maximum, replace all the 6
pistons. If necessary, replace the cylinder block.
10. INSPECT PISTON RING GROOVE CLEARANCE
Using a feeler gauge, measure the clearance between new pis-
ton ring and the wall of the piston ring groove.
Ring groove clearance:
No.1 0.040 - 0.080 mm (0.0016 - 0.0031 in.)
No.2 0.030 - 0.070 mm (0.0012 - 0.0028 in.)
If the clearance is not as specified, replace the piston.
11. INSPECT PISTON RING END GAP
(a) Insert the piston ring into the cylinder bore.
(b) Using a piston, push the piston ring a little beyond the bot-
tom of the ring travel, 105 mm (4.13 in.) from the top of the
cylinder block.
(c) Using a feeler gauge, measure the ring end gap.
Ring end gap:
If the end gap is greater than maximum, replace the piston ring.
If the end gap is greater than maximum, even with a new piston
ring, replace the cylinder block.

P02082
Z02381
Z02382
P02275
EM0227
EM-82
- ENGINE MECHANICAL (2JZ-GTE)CYLINDER BLOCK
1187 Author
: Date
:
1997 SUPRA (RM502U)
12. PINSPECT PISTON PIN FIT
At 80°C (176°F), you should be able to push the piston pin into
the piston pin hole with your thumb.
13. INSPECT CONNECTING ROD ALIGNMENT
Using a feeler gauge and rod aligner, check the connecting rod
alignment.

Check for out-of-alignment
Maximum out-of-alignment:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If out-of-alignment is greater than maximum, replace the con-
necting rod assembly.

Check for twist
Maximum twist:
0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
If twist is greater than maximum, replace the connecting rod as-
sembly.
14. INSPECT PISTON PIN OIL CLEARANCE
(a) Using a caliper gauge, measure the inside diameter of the
connecting rod bushing.
Bushing inside diameter:
22.005 - 22.014 mm (0.8663 - 0.8667 in.)
(b) Using a micrometer, measure the piston pin diameter.
Piston pin diameter:
21.997 - 22.006 mm (0.8660 - 0.8664 in.)
(c) Subtract the piston pin diameter measurement from the
bushing inside diameter measurement.
Standard oil clearance:
0.005 - 0.011 mm (0.0002 - 0.0004 in.)
Maximum oil clearance:
0.05 mm (0.0020 in.)
If the oil clearance is greater than maximum, replace the bush-
ing. If necessary, replace the piston and piston pin as a set.

P02143
P02459
About
20 mmCompressed
P02153
Z02383
ItemSTD mm (in.)
U/S 0.25 mm (in.)
Main journal
Crank pin61.984 - 62.000
(2.4403 - 2.4409)
51.982 - 52.000
(2.0465 - 2.0472)61.745 - 61.755
(2.4309 - 2.4313)
51.745 - 51.755
(0.0372 - 2.0376)
- ENGINE MECHANICAL (2JZ-GTE)CYLINDER BLOCK
EM-83
1188 Author
: Date
:
1997 SUPRA (RM502U)
(d) Check the piston pin fit at room temperature.
Coat the piston pin with engine oil and push it into the con-
necting rod with your thumb.
15. INSPECT CONNECTING ROD BOLTS
Using vernier calipers, measure the minimum diameter of the
compressed bolt at the measuring point.
Standard diameter: 8.1 - 8.3 mm (0.319 - 0.327 in.)
Minimum diameter: 8.0 mm (0.315 in.)
If the diameter is less than minimum, replace the connecting rod
bolt.
16. INSPECT CRANKSHAFT FOR RUNOUT
(a) Place the crankshaft on V-blocks.
(b) Using a dial indicator, measure the circle runout at the
center journal.
Maximum circle runout: 0.06 mm (0.0024 in.)
If the circle runout is greater than maximum, replace the crank-
shaft.
17. INSPECT MAIN JOURNALS AND CRANK PINS
(a) Using a micrometer, measure the diameter of each main
journal and crank pin.
Diameter:
If the diameter is not as specified, check the oil clearance. (See
page EM-71)
(b) Check each main journal and crank pin for taper and out-
of-round as shown.
Maximum taper and out-of round:
0.02 mm (0.0008 in.)
If the taper or out-of-round is greater than maximum, grind or
replace the crankshaft.

EM-84
- ENGINE MECHANICAL (2JZ-GTE)CYLINDER BLOCK
1189 Author
: Date
:
1997 SUPRA (RM502U)
18. IF NECESSARY, GRIND AND HONE MAIN
JOURNALS AND/OR CRANK PINS
(a) Grind and hone the main journals and/or crank pins to the
finished undersized diameter
(See procedure step 17).
(b) Install new main journal and/or crank pin undersized
bearings.

EM0AQ-02
P04473
P04794
SST
Z02384
Cut Position
P04795
SST
P04475
- ENGINE MECHANICAL (2JZ-GTE)CYLINDER BLOCK
EM-85
1190 Author
: Date
:
1997 SUPRA (RM502U)
REPLACEMENT
HINT:
There are 2 methods A and B to replace the oil seal as follows:
1. REPLACE CRANKSHAFT FRONT OIL SEAL
(a) If oil pump is removed from cylinder block.
(1) Using a screwdriver, pry out the oil seal.
(2) Using SST and a hammer, tap in a new oil seal until
its surface is flush with the oil pump body edge.
SST 09316-6001 1 (09316-00011)
(3) Apply MP grease to the oil seal lip.
(b) If oil pump is installed on cylinder block:
(1) Using a knife, cut off the oil seal lip.
(2) Using a screwdriver, pry out the oil seal.
NOTICE:
Be careful not to damage the crankshaft. Tape the screw-
driver tip.
(3) Apply MP grease to a new oil seal lip.
(4) Using SST and a hammer, tap in the oil seal until its
surface is flush with the oil pump body edge.
SST 09316-6001 1 (09316-00011)
2. REPLACE CRANKSHAFT REAR OIL SEAL
(a) If rear oil seal retainer is removed from cylinder block:
(1) Using a screwdriver and hammer, tap out the oil
seal.

P04796
SST
SST
Z02416
Cut Position
P02363
SST
P04793
SST
P04799
Oil Hole EM-86
- ENGINE MECHANICAL (2JZ-GTE)CYLINDER BLOCK
1191 Author
: Date
:
1997 SUPRA (RM502U)
(2) Using SST and a hammer, tap in a new oil seal until
its surface is flush with the rear oil seal retainer
edge.
SST 09223-15030, 09950-70010 (09951-07100)
(3) Apply MP grease to the oil seal lip.
(b) If rear oil seal retainer is installed on cylinder block:
(1) Using a knife, cut off the oil seal lip.
(2) Using a screwdriver, pry out the oil seal.
NOTICE:
Be careful not to damage the crankshaft. Tape the screw-
driver tip.
(3) Apply MP grease to a new oil seal lip.
(4) Using SST and a hammer, tap in the oil seal until its
surface is flush with the rear oil seal retainer edge.
SST 09223-15030, 09950-70010 (09951-07100)
3. REPLACE CONNECTING ROD BUSHING
(a) Using SST and a press, press out the bushing.
SST 09222-30010
(b) Align the oil holes of a new bushing and the connecting
rod.
(c) Using SST and a press, press in the bushing.
SST 09222-30010

EM6535
P02143
- ENGINE MECHANICAL (2JZ-GTE)CYLINDER BLOCK
EM-87
1192 Author
: Date
:
1997 SUPRA (RM502U)
(d) Using a pin hole grinder, bore the bushing to obtain the
standard specified clearance (See page EM-79) be-
tween the bushing and piston pin.
(e) Check the piston pin fit at room temperature.
Coat the piston pin with engine oil and push it into the con-
necting rod with your thumb.

EM1DZ-01
P02438
P02455
Front
Mark
P02656
Z02417
Code Mark
Code Mark No.1
No.2 EM-88
- ENGINE MECHANICAL (2JZ-GTE)CYLINDER BLOCK
1193 Author
: Date
:
1997 SUPRA (RM502U)
REASSEMBLY
HINT:

Thoroughly clean all parts to be assembled.

Before installing the parts, apply fresh engine oil to all slid-
ing and rotating surfaces.

Replace all gaskets, O-rings and oil seals with new parts.
1. ASSEMBLE PISTON AND CONNECTING ROD
(a) Install a new snap ring at one end of the piston pin hole.
HINT:
Be sure that end gap of the snap ring is not aligned with the pin
hole cutout portion of the piston.
(b) Gradually heat the piston to about 80°C (176°F).
(c) Coat the piston pin with engine oil.
(d) Align the front marks of the piston and connecting rod,
and push in the piston pin with your thumb.
(e) Install a new snap ring at the other end of the piston pin
hole.
HINT:
Be sure that end gap of the snap ring is not aligned with the pin
hole cutout portion of the piston.
2. INSTALL PISTON RINGS
(a) Install the oil ring expander and 2 side rails by hand.
(b) Using a piston ring expander, install the 2 compression
rings with the code mark facing up.
Code mark:
No.1 2T
No.2 2N