TOYOTA SUPRA 1997 Service Repair Manual

W02668
Cap
Strainer
ReservoirSnap Ring
Boot
No.1 Piston and Spring
No.2 Piston and Spring
Reservoir Set Screw Grommet
Piston Stopper Bolt

Gasket

Non-reusable part
Lithium soap base glycol grease
- BRAKEBRAKE MASTER CYLINDER
BR-1 1
1811 Author
: Date
:
1997 SUPRA (RM502U)

BR0GF-01
W02790
SST
W02791
BR-12
- BRAKEBRAKE MASTER CYLINDER
1812 Author
: Date
:
1997 SUPRA (RM502U)
REMOVAL
1. DISCONNECT LEVEL WARNING SWITCH
CONNECTOR
2. DRAW OUT FLUID WITH SYRINGE
NOTICE:
Do not let brake fluid remain on a painted surface. Wash it
off immediately.
3. DISCONNECT BRAKE LINES
Using SST, disconnect the brake lines from the master cylinder.
SST 09023-00100
Torque: 15 N´m (155 kgf´cm, 11 ft´lbf)
4. REMOVE MASTER CYLINDER
(a) Remove the 2 nuts.
Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)
(b) 2JZ-GE Engine:
Remove the master cylinder and gasket from the brake
booster.
(c) 2JZ-GTE Engine:
Remove the vacuum hose clamp, master cylinder and
gasket from the brake booster.

BR0GG-01
W02792
W02660
W02661
- BRAKEBRAKE MASTER CYLINDER
BR-13
1813 Author
: Date
:
1997 SUPRA (RM502U)
DISASSEMBLY
1. REMOVE MASTER CYLINDER BOOT
Using a screwdriver, remove the master cylinder boot.
NOTICE:
At the time of reassembly, please refer to the following
item.
Facing the UP mark on the master cylinder boot upwards,
install the cylinder boot to the master cylinder.
2. REMOVE RESERVOIR CAP AND STRAINER
3. REMOVE RESERVOIR
Remove the set screw and pull out the reservoir.
Torque: 1.8 N´m (18 kgf´cm, 16 in.´lbf)
4. REMOVE 2 GROMMETS
5. PLACE CYLINDER IN VISE
6. REMOVE PISTON STOPPER BOLT
Using a screwdriver, push the pistons in all the way and remove
the No.2 piston stopper bolt and gasket.
Torque: 10 N´m (100 kgf´cm, 7 ft´lbf)
7. REMOVE 2 PISTONS
(a) Push in the piston with a screwdriver and remove the
snap ring with snap ring pliers.
HINT:
Tape the screwdriver tip before use.
(b) Remove the No. 1 piston and spring by hand, pulling
straight out, not at an angle.
NOTICE:

If pulled out and install at an angle, there is a possibil-
ity that the cylinder bore could be damaged.

At the time of reassembly, be careful not to damage
the rubber lips on the pistons.

R12236
A BR-14
- BRAKEBRAKE MASTER CYLINDER
1814 Author
: Date
:
1997 SUPRA (RM502U)
(c) Place a rag and 2 wooden blocks on the work table and
lightly tap the cylinder flange against the block edges until
the piston drops out of the cylinder.
HINT:
Make sure the distance (A) from the rag to the top of the blocks
is at least 100 mm (3.94 in.).

BR0GJ-01
- BRAKEBRAKE MASTER CYLINDER
BR-17
1817 Author
: Date
:
1997 SUPRA (RM502U)
INSTALLATION
Installation is in the reverse order of removal (See page BR-12).
1. BEFORE INSTALLATION, ADJUST LENGTH OF BRAKE BOOSTER PUSH ROD
(See page BR-21)
2. AFTER INSTALLATION, FILL BRAKE FLUID AND BLEED BRAKE SYSTEM (See page BR-5)
3. CHECK FOR LEAKS, CHECK AND ADJUST BRAKE PEDAL (See page BR-7)

BR0GL-03
W02993
Pedal Bracket Stay
Return Spring
Clevis Pin ClevisClip
Gasket Brake Booster

Gasket Master Cylinder
Level Warning Switch Connector
2JZ-GTE Engine:
Vacuum Hose Clamp

Non-reusable part
- BRAKEBRAKE BOOSTER ASSEMBLY
BR-19
1819 Author
: Date
:
1997 SUPRA (RM502U)
COMPONENTS

BR0GM-02
R09739
R07122
BR-20
- BRAKEBRAKE BOOSTER ASSEMBLY
1820 Author
: Date
:
1997 SUPRA (RM502U)
REMOVAL
1. REMOVE THESE PARTS

Master cylinder (See page BR-12)

Vacuum hose

Clip, clevis pin and return spring
2. REMOVE PEDAL BRACKET STAY
(a) Remove the steering column assembly (See page
SR-1 1).
(b) Remove the bolt and nut.
(c) Remove the pedal bracket stay.
3. REMOVE BRAKE BOOSTER
(a) Remove the 4 booster installation nuts and clevis.
(b) Remove the booster and gasket.

BR0GN-03
F03521
SST
Gasket
N00744
SST
- BRAKEBRAKE BOOSTER ASSEMBLY
BR-21
1821 Author
: Date
:
1997 SUPRA (RM502U)
INSTALLATION
1. INSTALL BRAKE BOOSTER
(a) Install the booster and a new gasket.
(b) Install the clevis to the operating rod.
(c) Install and torque the booster installation nuts.
Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)
(d) Insert the clevis pin into the clevis and brake pedal, and
install the clip to the clevis pin.
(e) Install the pedal return spring.
2. ADJUST LENGTH OF BOOSTER PUSH ROD
(a) Install the gasket on the master cylinder.
(b) Set the SST on the gasket, and lower the pin until its tip
slightly touches the piston.
SST 09737-00010
(c) Turn the SST upside down, and set it on the booster.
SST 09737-00010
(d) Measure the clearance between the booster push rod
and pin head (SST).
Clearance: 0 mm (0 in.)
(e) Adjust the booster push rod length until the push rod light-
ly touches the pin head.
HINT:
When adjusting the push rod, depress the brake pedal enough
so that the push rod sticks out.
3. INSTALL PEDAL BRACKET STAY
(a) Install the pedal bracket stay.
(b) Install the bolt and nut.
(c) Install the steering column assembly (See page
SR-21).
4. INSTALL THESE PARTS

Vacuum hose

Master cylinder (See page BR-17)
5. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND
BLEED BRAKE SYSTEM (See page BR-5)
6. CHECK FOR FLUID LEAKAGE
7. CHECK AND ADJUST BRAKE PEDAL
(See page BR-7)
8. DO OPERATIONAL CHECK (See page BR-18)

BR0GQ-01
F02616
Anti-rattle Spring
Outer Pad
Anti-squeal Shim
Pin
Pad Spacer Inner Pad
Anti-squeal Shim
Clip
Disc brake grease
- BRAKEFRONT BRAKE PAD (2JZ-GTE)
BR-25
1825 Author
: Date
:
1997 SUPRA (RM502U)
FRONT BRAKE PAD (2JZ-GTE)
COMPONENTS

BR0GR-01
R07124
Z09010Z09010
R07127
BR-26
- BRAKEFRONT BRAKE PAD (2JZ-GTE)
1826 Author
: Date
:
1997 SUPRA (RM502U)
REPLACEMENT
1. REMOVE FRONT WHEEL
Remove the wheel and temporarily fasten the disc with the hub
nuts.
2. INSPECT PAD LINING THICKNESS
Check the pad thickness and replace pads if they are not within
specification.
Minimum thickness: 1.0 mm (0.039 in.)
3. REMOVE THESE PARTS
(a) Clip and 2 pins
(b) Anti-rattle spring
(c) 2 pads
(d) 2 pad spacers
(e) 2 anti-squeal shims
NOTICE:
The anti-rattle spring, clip and pad spacers can be used
again provided that they have sufficient rebound, no de-
formation, cracks or wear, and have had all rust, dirt and
foreign particles cleaned off.
4. CHECK DISC THICKNESS AND RUNOUT
(See page BR-39)
5. INSTALL NEW PADS
NOTICE:
When replacing worn pads, the anti-squeal shims must be
replaced together with the pads.
(a) Draw out a small amount of brake fluid from the reservoir.
(b) Press in the pistons with a hammer handle or equivalent.
HINT:

Always change the pads on one wheel at a time as there
is a possibility of the opposite piston flying out.

If the piston is difficult to push in, loosen the bleeder plug
and push in the piston while letting some brake fluid es-
cape.