TOYOTA SUPRA 1997 Service Repair Manual

P02171
Front MarkUpper Side
Rail
Lower Side
Rail No.1
Compression
No.2
Compression (Cavity)Expander
P02139
Z16762
5 mm
Hexagon
Wrench
P04797
20.0 mm
23.0 mmNo.1 Others
P04476
- ENGINE MECHANICAL (2JZ-GTE)CYLINDER BLOCK
EM-89
1194 Author
: Date
:
1997 SUPRA (RM502U)
(c) Position the piston rings so that the ring ends are as
shown.
NOTICE:
Do not align the piston ring ends.
3. INSTALL BEARINGS
(a) Align the bearing claw with the groove of the connecting
rod and connecting cap.
(b) Install the bearings in the connecting rod and connecting
rod cap.
NOTICE:
Apply a generous amount of oil on the sliding surface of the
bearing, and not on the back of it or on the surface to which
it is installed.
4. INSTALL OIL NOZZLES (WITH RELIEF VALVES)
Using a 5 mm hexagon wrench, install the oil nozzle with the
bolt. Install the 6 oil nozzles.
Torque: 8.8 N´m (90 kgf´cm, 78 in.´lbf)
5. INSTALL MAIN BEARINGS
HINT:

Main bearings come in widths of 20.0 mm (0.787 in.) and
23.0 mm (0.906 in.). Install the 23.0 mm bearings in the
No.1 cylinder block journal position with the main bearing
cap. Install the 20.0 mm bearings in the other positions.

Upper bearings have an oil groove and oil holes; lower
bearings do not.
(a) Align the bearing claw with the claw groove of the main
bearing cap or cylinder block.
NOTICE:
Install the bearing with the oil hole in the cylinder block.

P02671
P04477
P02430
P02160
P02284
14 13
12 11
10 9
85
4 7
6 3
2 1 EM-90
- ENGINE MECHANICAL (2JZ-GTE)CYLINDER BLOCK
1195 Author
: Date
:
1997 SUPRA (RM502U)
(b) Install the bearings in the cylinder block and main bearing
caps.
6. INSTALL UPPER THRUST WASHERS
Install the 2 thrust washers under the No.4 main journal position
of the cylinder block with the oil grooves facing outward.
7. PLACE CRANKSHAFT ON CYLINDER BLOCK
8. PLACE MAIN BEARING CAP AND LOWER THRUST
WASHERS ON CYLINDER BLOCK
(a) Install the lower thrust washers on the No.4 main bearing
with the grooves facing outward.
(b) Install the main bearing caps in numerical order with the
arrows facing forward.
9. INSTALL MAIN BEARING CAP BOLTS
HINT:

The main bearing cap bolts are tightened in 2 progressive
steps (steps (b) and (d)).

If any of the main bearing bolts break or deform, replace
them.
(a) Apply a light coat of engine oil on the threads and under
the heads of the main bearing cap bolts.
(b) Install and uniformly tighten the 14 main bearing cap
bolts, in several passes, in the sequence shown.
Torque: 44 N´m (450 kgf´cm, 33 ft´lbf)
If any one of the main bearing cap bolts does not meet the
torque specification, replace the main bearing cap bolt.

P02440
90°Painted Mark
90°
Z02418
Front Mark
(Cavity)
Front
P04479
P02426
P02419
Painted
Mark Front
- ENGINE MECHANICAL (2JZ-GTE)CYLINDER BLOCK
EM-91
1196 Author
: Date
:
1997 SUPRA (RM502U)
(c) Mark the front of the main bearing cap bolt head with
paint.
(d) Retighten the main bearing cap bolts 90° in the numerical
order shown above.
(e) Check that the painted mark is now at a 90° angle to the
front.
(f) Check that the crankshaft turns smoothly.
10. CHECK CRANKSHAFT THRUST CLEARANCE
(See page EM-71)
11. INSTALL PISTON AND CONNECTING ROD
ASSEMBLIES
Using a piston ring compressor, push the correctly numbered
piston and connecting rod assemblies into each cylinder with
the front mark of the piston facing forward.
12. PLACE CONNECTING ROD CAP ON CONNECTING
ROD
(a) Match the numbered connecting rod cap with the con-
necting rod.
(b) Install the connecting rod cap with by aligning the dowel
pin to the corresponding hole.
13. INSTALL CONNECTING ROD CAP BOLTS
HINT:

The connecting rod cap bolts are tightened in 2 progres-
sive steps (steps (b) and (d)).

If any of the connecting rod bolts break or deform, replace
them.
(a) Apply a light coat of engine oil on the threads and under
the heads of the connecting rod cap bolts.
(b) At first, install and alternately tighten the bolts of the con-
necting rod cap in several passes.
Torque: 29 N´m (300 kgf´cm, 22 ft´lbf)
If any one of the connecting rod cap bolts does not meet the
torque specification, replace the cap bolt.
(c) Mark the front of the connecting rod cap bolt with paint.

P02420
90°Painted Mark
90°
P02197
Seal Width
2 - 3 mm
Seal
Packing
P02104
Z16761
Adhesive EM-92
- ENGINE MECHANICAL (2JZ-GTE)CYLINDER BLOCK
1197 Author
: Date
:
1997 SUPRA (RM502U)
(d) Retighten the connecting rod cap bolts 90° in the numeri-
cal order shown.
(e) Check that the painted mark is now at a 90° angle to the
front.
(f) Check that the crankshaft turns smoothly.
14. CHECK CONNECTING ROD THRUST CLEARANCE
(See page EM-79)
15. INSTALL REAR OIL SEAL RETAINER
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the retainer
and cylinder block.

Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces and sealing groove.

Thoroughly clean all components to remove all de-
bris.

Using a non-residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the retainer as shown in the illustra-
tion.
Seal packing:
Part No. 08826-00080 or equivalent

Install a nozzle that has been cut to a 2 - 3 mm (0.08
- 0.12 in.) opening.

Parts must be assembled within 3 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.

Immediately remove nozzle from the tube and rein-
stall cap.
(c) Install the retainer with the 6 bolts.
Torque: 6.0 N´m (60 kgf´cm, 53 in.´lbf)
16. INSTALL OIL PUMP (See page LU-16)
17. INSTALL WATER PUMP (See page CO-1 1)
18. INSTALL CRANKSHAFT POSITION SENSOR
Torque: 9.0 N´m (90 kgf´cm, 80 in.´lbf)
19. INSTALL RH ENGINE MOUNTING BRACKET AND
INSULATOR ASSEMBLY
Torque: 59 N´m (590 kgf´cm, 44 ft´lbf)
20. INSTALL ENGINE COOLANT DRAIN PLUG
Torque: 30 N´m (300 kgf´cm, 22 ft´lbf)
21. INSTALL UNION FOR OIL COOLER HOSE
(a) Apply adhesive to 2 or 3 threads of the union.
Adhesive:
Part No. 08833-00070, THREE BOND 1324,
or equivalent
(b) Install the union.
Torque: 40 N´m (400 kgf´cm, 30 ft´lbf)

P10820
Adhesive
P13197
Oil Pressure
SwitchKnock Sensor
- ENGINE MECHANICAL (2JZ-GTE)CYLINDER BLOCK
EM-93
1198 Author
: Date
:
1997 SUPRA (RM502U)
22. INSTALL OIL PRESSURE SWITCH AND KNOCK SEN-
SORS
(a) Install the union nut with a new gasket.
SST 09816-30010
Torque: 55 N´m (550 kgf´cm, 41 ft´lbf)
(b) Apply adhesive to 2 or 3 threads of the oil pressure switch.
Adhesive:
Part No. 08833-00080, THREE BOND 1344,
LOCKTITE 242 or equivalent
(c) Using SST, install the switch and sensors.
SST 09816-30010
Torque:
OIl pressure switch: 14 N´m (150 kgf´cm, 11 ft´lbf)
Knock sensor: 44 N´m (450 kgf´cm, 33 ft´lbf)
23. INSTALL FUEL PIPE SUPPORT
Torque: 28 N´m (290 kgf´cm, 21 ft´lbf)
24. INSTALL LH ENGINE MOUNTING BRACKET AND IN-
SULATOR ASSEMBLY
Torque: 58 N´m (590 kgf´cm, 44 ft´lbf)
25. INSTALL OIL FILTER BRACKET
(a) Check and clean the oil filter bracket installation.
(b) Place a new O-ring in position on the oil filter bracket.
(c) Apply clean engine oil to the O-ring.
(d) Install a new gasket to the union bolt.
(e) Install the oil filter bracket with the union bolt.
Torque: 90 N´m (900 kgf´cm, 66 ft´lbf)
26. INSTALL NO.2 WATER BYPASS PIPE WITH HOSE
(a) Install a new gasket to the water pump.
(b) Install the water bypass pipe with the 2 bolts and 2 nuts.
Torque: 21 N´m (210 kgf´cm, 15 ft´lbf)
27. INSTALL OIL COOLER (See page LU-22)
28. INSTALL CYLINDER HEAD (See page EM-47)
29. INSTALL TIMING PULLEYS AND BELT (See page
EM-21)
30. INSTALL GENERATOR (See page CH-18)
31. REMOVE ENGINE STAND FROM ENGINE

Z16724
8
8
5
47 63
2 1
M/T
Z16725
M/T
90°
Painted Mark 90°
Z16739
A/T
Rear Plate
Z16736
A/T
1
2
34
56
7 8 EM-94
- ENGINE MECHANICAL (2JZ-GTE)CYLINDER BLOCK
1199 Author
: Date
:
1997 SUPRA (RM502U)
32. M/T:
INSTALL FLYWHEEL
HINT:
The flywheel bolts are tightened in 2 progressive step, (b) and
(d).
(a) Install the flywheel on the crankshaft.
(b) Install and uniformly tighten the 8 bolts, in several passes,
in the sequence shown.
Torque: 49 N´m (500 kgf´cm, 36 ft´lbf)
(c) Mark the flywheel bolt with paint.
(d) Retighten the flywheel bolts by an additional 90°.
(e) Check that the painted mark is now at a 90° angle to (d).
33. A/T:
INSTALL DRIVE PLATE
(a) Install the front spacer, drive plate and rear plate on the
crankshaft.
(b) Apply adhesive to 2 or 3 threads of the mounting bolt end.
Adhesive:
Part No. 08833-00070, THREE BOND 1324 or
equivalent
(c) Install and uniformly tighten the 8 bolts, in several passes,
in the sequence shown.
Torque: 83 N´m (850 kgf´cm, 61 ft´lbf)

EM0AS-02
S00574
Z18960
Support
Ring
TailpipeTailpipe
Baffle

Gasket RingCenter Exhaust PipeHeat Insulator

Gasket
Ring
Heat InsulatorHeat Insulator

Gasket

Gasket
Gasket

GasketHeat Insulator
Heated Oxygen Sensor
Pipe Support Bracket No.2 Front Exhaust Pipe
(with Front TWC)





Non-reusable partNormal RoofSport Roof
Front Exhaust Pipe
(with Rear TWC)
(Bank 1 Sensor 2)
- ENGINE MECHANICAL (2JZ-GTE)EXHAUST SYSTEM
EM-95
1200 Author
: Date
:
1997 SUPRA (RM502U)
EXHAUST SYSTEM
COMPONENTS

PP0QF-01
PP-12
- PREPARATIONENGINE MECHANICAL (2JZ-GTE)
58 Author
: Date
:
1997 SUPRA (RM502U)
EQUIPMENT
OBDII scan toolEngine speed
Caliper gauge
CO/HC meter
Compression gauge
Connecting rod aligner
Cylinder gauge
Dial indicator
Dye penetrant
Engine tune-up tester
Heater
Micrometer
Mirror
Magnetic finger
Piston ring compressor
Piston ring expander
Plastigage
Precision straight edge
Spring testerValve spring
Steel squareValve spring
Thermometer
Torque wrench
Valve seat cutter
Vernier calipers
V-block

EM0A7-02
P11550
CO/HC Meter
- ENGINE MECHANICAL (2JZ-GTE)CO/HC
EM-1
1106 Author
: Date
:
1997 SUPRA (RM502U)
CO/HC
INSPECTION
HINT:
This check is used only to determine whether or not the idle CO/
HC complies with regulations.
1. INITIAL CONDITIONS
(a) Engine at normal operating temperature
(b) Air cleaner installed
(c) All pipes and hoses of air induction system connected
(d) All accessories switched OFF
(e) All vacuum lines properly connected
HINT:
All vacuum hoses for EGR system, etc. should be properly con-
nected.
(f) SFI system wiring connectors fully plugged
(g) Ignition timing checked correctly
(h) Transmission in neutral position
(i) Tachometer and CO/HC meter calibrated by hand
2. START ENGINE
3. RACE ENGINE AT 2,500 RPM FOR APPROX. 180
SECONDS
4. INSERT CO/HC METER TESTING PROBE AT LEAST
40 cm (1.3 ft) INTO TAILPIPE DURING IDLING
5. IMMEDIATELY CHECK CO/HC CONCENTRATION AT
IDLE AND/OR 2,500 RPM
HINT:
When performing the 2 mode (2,500 rpm and idle) test, follow
the measurement order prescribed by the applicable local regu-
lations.

EM-2
- ENGINE MECHANICAL (2JZ-GTE)CO/HC
1107 Author
: Date
:
1997 SUPRA (RM502U)
If the CO/HC concentration does not comply with regulations,
troubleshoot in the order given below.
(1) Check heated oxygen sensors operation.
(See page SF-82)
(2) See the table below for possible causes, and then
inspect and correct the applicable causes if neces-
sary.
COHCPhenomenonCauses
NormalHighRough idle1. Faulty ignitions:

Incorrect timing

Fouled, shorted or improperly gapped plugs
2. Incorrect valve clearance
3. Leaky EGR valve
4.Leaky intake and exhaust valves
5.Leaky cylinder
LowHighRough idle
(Fluctuating HC reading)1. Vacuum leaks:

PCV hose

EGR valve

Intake manifold

Air intake chamber

Throttle body

IAC valve

Brake booster line
2. Lean mixture causing misfire
HighHighRough idle
(Black smoke from exhaust)1. Restricted air filter:
2. Faulty SFI system:

Faulty fuel pressure regulator

Clogged fuel return line

Defective ECT sensor

Defective turbo pressure sensor

Faulty ECM

Faulty injector

Faulty throttle position sensor

Faulty MAF meter