brake TOYOTA SUPRA 1997 Service Repair Manual

Q04160
Push Rod Play and
Freeplay Adjust Point
Pedal
HeightPedal Height
Adjust Point
Push Rod PlayCL03Z-01
CL0102Pedal Freeplay
Z13785
25 mm (0.98 in.) or more
Full Pedal Stroke Full Stroke
End PositionRelease
Point
- CLUTCHCLUTCH PEDAL
CL-3
1544 Author
: Date
:
1997 SUPRA (RM502U)
CLUTCH PEDAL
INSPECTION
1. CHECK PEDAL HEIGHT
Pedal height from asphalt sheet:
146.2 - 156.2 mm (5.76 - 6.15 in.)
2. IF NECESSARY, ADJUST PEDAL HEIGHT
Loosen the lock nut and clutch switch until the height is correct.
Tighten the lock nut.
HINT:
Before rotating the clutch switch for pedal height adjustment,
disconnect the clutch switch connector.
3. CHECK PEDAL FREEPLAY AND PUSH ROD PLAY
Push in on the pedal until the beginning of clutch resistance is
felt.
Pedal freeplay: 5.0 - 15.0 mm (0.197 - 0.591 in.)
Gently push on the pedal until the resistance begins to increase
a little.
Push rod play at pedal top:
1.0 - 5.0 mm (0.039 - 0.197 in.)
4. IF NECESSARY, ADJUST PEDAL FREEPLAY AND
PUSH ROD PLAY
(a) Loosen the lock nut and turn the push rod until the free-
play and push rod play are correct.
(b) Tighten the lock nut.
(c) After adjusting the pedal freeplay, check the pedal height.
5. INSPECT FULL PEDAL STROKE
Full pedal stroke: 132.0 - 138.0 mm (5.20 - 5.43 in.)
6. INSPECT CLUTCH RELEASE POINT
(a) Pull the parking brake lever and install wheel stopper.
(b) Start the engine and idle the engine.
(c) Without depressing the clutch pedal, slowly shift the shift
lever into the reverse position until the gears contact.
(d) Gradually depress the clutch pedal and measure the
stroke distance from the point the gear noise stops (re-
lease point) up to the full stroke end position.

Illustration:
what to do and where
21. CHECK PISTON STROKE OF OVERDRIVE BRAKE
(a) Place SST and a dial indicator onto the overdrive brake
piston as shown in the illustration.
Task heading : what to do
SST 09350-30020 (09350-06120)
Set part No. Component part No.
Detailed text : how to do task
(b) Measure the stroke applying and releasing the compressed
Piston stroke: 1.40
1.70 mm (0.0551
0.0669 in.)
Specification
air (392 - 785 kPa, 4 - 8 kgf.cm2 or 57 - 114 psi) as
shown in the illustration. IN-2
- INTRODUCTIONHOW TO USE THIS MANUAL
2 Author
: Date
:
1997 SUPRA (RM502U)
The procedures are presented in a step-by-step format:

The illustration shows what to do and where to do it.

The task heading tells what to do.

The detailed text tells how to perform the task and gives other information such as specifications
and warnings.
Example:
This format provides the experienced technician with a FAST TRACK to the information needed. The upper
case task heading can be read at a glance when necessary, and the text below it provides detailed informa-
tion. Important specifications and warnings always stand out in bold type.
6. REFERENCES
References have been kept to a minimum. However, when they are required you are given the page to refer
to.
7. SPECIFICATIONS
Specifications are presented in bold type throughout the text where needed. You never have to leave the
procedure to look up your specifications. They are also found in Service Specifications section, for quick
reference.

CAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other
people.

NOTICES are also presented in bold type, and indicate the possibility of damage to the compo-
nents being repaired.

HINTS are separated from the text but do not appear in bold. They provide additional information
to help you perform the repair efficiently.
8. SI UNIT
The UNITS given in this manual are primarily expressed according to the SI UNIT (International System of
Unit), and alternately expressed in the metric system and in the English System.
Example:
Torque: 30 N´m (310 kgf´cm, 22 ft´lbf)

IN04F-02
- INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMSIN-17
17 Author
: Date
:
1997 SUPRA (RM502U)
HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS
GENERAL INFORMATION
A large number of ECU controlled systems are used in the TOYOTA SUPRA. In general, the ECU controlled
system is considered to be a very intricate system requiring a high level of technical knowledge and expert
skill to troubleshoot. However, the fact is that if you proceed to inspect the circuits one by one, troubleshoot-
ing of these systems is not complex. If you have adequate understanding of the system and a basic knowl-
edge of electricity, accurate diagnosis and necessary repair can be performed to locate and fix the problem.
This manual is designed through emphasis of the above standpoint to help service technicians perform ac-
curate and effective troubleshooting, and is compiled for the following major ECU controlled systems:
SystemPage
1. Engine (2JZ-GE)DI-1
2. Engine (2JZ-GTE)DI-145
3. Automatic Transmission (2JZ-GE)DI-316
4. Automatic Transmission (2JZ-GTE)DI-371
5. Anti-Lock Brake SystemDI-440
6. ABS & Traction control SystemDI-499
7. Supplemental Restraint SystemDI-555
8. Theft Deterrent SystemDI-608
9. Cruise Control SystemDI-660
11. Air Conditioning SystemDI-71 1
The troubleshooting procedure and how to make use of it are described on the above pages.
FOR USING OBDII SCAN TOOL OR TOYOTA HAND-HELD TESTER

Before using the OBDII scan tool or TOYOTA hand-held tester, the OBDII scan tool's instruction book
or TOYOTA hand-held tester's operator manual should be read thoroughly.

If the OBDII scan tool or TOYOTA hand-held tester cannot communicate with ECU controlled systems
when you have connected the cable of the OBDII scan tool or TOYOTA hand-held tester to DLC3,
turned the ignition switch ON and operated the scan tool, there is a problem on the vehicle side or tool
side.
(1) If communication is normal when the tool is connected to another vehicle, inspect the diagnosis
data link line (Bus
line) or ECU power circuit of the vehicle.
(2) If communication is still not possible when the tool is connected to another vehicle, the problem
is probably in the tool itself, so perform the Self Test procedures outlined in the Tester Operator's
Manual.

DIAGNOSTIC TROUBLE CODE CHECK PROCEDURE
Diagnostic Trouble
Code Check (Make a
note of and then clear)Confirmation
of SymptomsDiagnostic Trouble
Code CheckProblem Condition
Diagnostic Trouble
Code DisplayProblem symptoms
existSame diagnostic
trouble code is
displayedProblem is still occurring in the diagnostic
circuit.
Normal code is
displayedThe problem is still occurring in a place
other than in the diagnostic circuit.
(The diagnostic trouble code displayed
first is either for a past problem or it is a
secondary problem.)
No problem
symptoms existThe problem occurred in the diagnostic
circuit in the past.
Normal Code DisplayProblem symptoms
existNormal code is
displayedThe problem is still occurring in a place
other than in the diagnostic circuit.
No problem
symptoms existNormal code is
displayedThe problem occurred in a place other
than in the diagnostic circuit in the past.
IN-20- INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
20 Author
: Date
:
1997 SUPRA (RM502U)
2. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE CHECK
The diagnostic system in the TOYOTA SUPRA fulfills various functions. The first function is the Diagnostic
Trouble Code Check in which a malfunction in the signal circuits to the ECU is stored in code in the ECU
memory at the time of occurrence, to be output by the technician during troubleshooting. Another function
is the Input Signal Check which checks if the signals from various switches are sent to the ECU correctly.
By using these check functions, the problem areas can be narrowed down quickly and troubleshooting can
be performed effectively. Diagnostic functions are incorporated in the following systems in the TOYOTA SU-
PRA.
SystemDiagnostic Trouble
Code CheckInput Signal Check
(Sensor Check)Other Diagnosis
Function
Engine
Automatic Transmission
Anti-Lock Brake System
ABS & Traction Control System
Supplemental Restraint System
Cruise Control
Air Conditioning (with Check
Mode)
 (with Check
Mode)









Diagnostic Test
Mode
Diagnostic Test
Mode
Actuator Check
In diagnostic trouble code check, it is very important to determine whether the problem indicated by the diag-
nostic trouble code is still occurring or occurred in the past but returned to normal at present. In addition,
it must be checked in the problem symptom check whether the malfunction indicated by the diagnostic
trouble code is directly related to the problem symptom or not. For this reason, the diagnostic trouble codes
should be checked before and after the symptom confirmation to determine the current conditions, as shown
in the table below. If this is not done, it may, depending on the case, result in unnecessary troubleshooting
for normally operating systems, thus making it more difficult to locate the problem, or in repairs not pertinent
to the problem. Therefore, always follow the procedure in correct order and perform the diagnostic trouble
code check.

IN04I-01
- INTRODUCTIONTERMS
IN-33
33 Author
: Date
:
1997 SUPRA (RM502U)
TERMS
ABBREVIATIONS USED IN THIS MANUAL
AbbreviationsMeaning
ABSAnti-Lock Brake System
ALRAutomatic Locking Retractor
APPROX.Approximately
A/T, ATMAutomatic Transmission
AT FAutomatic Transmission Fluid
BTDCBefore Top Dead Center
CBCircuit Breaker
CDCompact Disc
CRSChild Restraint System
DOHCDouble Over Head Cam
DPDash Pot
ECUElectronic Control Unit
ELREmergency Locking Retractor
ESAElectronic Spark Advance
EXExhaust (Manifold, Valve)
FIPGFormed in Place Gasket
FLFusible Link
FrFront
H-FuseHigh Current Fuse
IGIgnition
INIntake (Manifold, Valve)
J/BJunction Block
LEDLight Emitting Diode
LHLeft-Hand
LLCLong Life Coolant (Year Around Coolant)
LSDLimited Slip Differential
Max.Maximum
Min.Minimum
MPMultipurpose
M/TManual Transmission
O/D, ODOverdrive
O/SOversize
P&BVProportioning and Bypass Valve
PCVPositive Crankcase Ventilation
PPSProgressive Power Steering
PSPower Steering
RHRight-Hand
RrRear
SRSSupplemental Restraint System
SSMSpecial Service Materials
SSTSpecial Service Tools
STDStandard

38SUPRAÐNEW FEATURES
2. Sound Absorbing Materials
Seal material has been newly provided to the bottom of the front pillar, and a quarter service hole cover has been
newly provided to the quarter portion in order to reduce road noise while driving.
The material of sound absorbing material used in the roof side inner garnish, quarter trim, deck side trim and deck
rear trim has been changed to reduce road noise.

CRUISE CONTROL SYSTEM
1. Actuator
The '97 Supra has adopted a new motor type actuator that is both lightweight and simple in construction.
The basic construction and operation of this actuator are the same as in the '96 4Runner with 5VZ±FE engine.
For details, see the 1996 4Runner New Car Features (Pub. No. NCF126U), page 71.
2. Cruise Control ECU
Manual Cancel Function
The manual cancel function, which cancels the cruise control when the parking brake is operated, has been
discontinued.

38SUPRAÐNEW FEATURES
3. Sound Absorbing Materials
Seal material has been newly provided to the bottom of the front pillar, and a quarter service hole cover has been
newly provided to the quarter portion in order to reduce road noise while driving.
The material of sound absorbing material used in the roof side inner garnish, quarter trim, deck side trim and deck
rear trim has been changed to reduce road noise.

CRUISE CONTROL SYSTEM
1. Actuator
The '97 Supra has adopted a new motor type actuator that is both lightweight and simple in construction.
The basic construction and operation of this actuator are the same as in the '96 4Runner with 5VZ±FE engine.
For details, see the 1996 4Runner New Car Features (Pub. No. NCF126U), page 71.
2. Cruise Control ECU
Manual Cancel Function
The manual cancel function, which cancels the cruise control when the parking brake is operated, has been
discontinued.

29 SUPRAÐNEW FEATURES
 DRIVE SHAFT
The drive shaft outboard joint of the 2JZ±GE engine model has been changed from the cross±groove type CJV
(Constant±Velocity Joint) to the Rzeppa type CVJ.
As in the '96 model, the 2JZ±GTE engine model uses the drive shaft consisting of cross±groove type CVJs for both
the inboard and outboard joints.
 BRAKES
1. General
The size of the master cylinder for the 2JZ±GTE engine model has been increased to realize excellent brake feeling.
The ABS actuator has been changed from the conventional three±position solenoid valves to a combination of
compact two±position solenoid valves, thus achieving a compact and lightweight configuration.
3±channel type ABS with 4±speed sensor is used on the 2JZ±GE engine model.
4±channel type ABS with 4±speed sensors and linear type deceleration sensor is used on the 2JZ±GTE engine
model.

Specifications
Model
'97 Model '96 Model
Engine Type2JZ GE2JZ GTE2JZ GE2JZ GTEItem2JZ±GE2JZ±GTE2JZ±GE2JZ±GTE
MasterTypeTandemuuuMaster
CylinderDia. mm (in.)25.4 (1.00)26.9 (1.06)25.4 (1.00)u
ABS Type
3 Channel Type
ABS with
4±Speed Sensors
4 Channel Type
ABS with
4±Speed Sensors
and Linear Type
Deceleration Sensor4±Channel Type
ABS with 4±Speed
Sensor and Lateral
Acceleration Sensors
u
ABS Type Actuator
6 Two Position
Solenoid Valves8 Two Position
Solenoid Valves4 Three Position
Solenoid Valvesu

30SUPRAÐNEW FEATURES
2. ABS
General
The ABS (Anti±Lock Brake System) is designed to control the brake fluid pressure of the brake wheel cylinder to
help prevent wheel lock±up in instances of panic braking, and thus maintaining vehicle directional stability and
control.
System Diagram

34SUPRAÐNEW FEATURES
c. Operation
The hydraulic system of the ABS has 3 or 4 circuits. Although the hydraulic circuit described below has 1 circuit,
it is applicable to other circuits as well.
i) During Normal Braking (ABS not Activated)
During normal braking, the ABS is not activated and
the ECU dose not send control signal.
When the brake pedal is depressed, the fluid passes
from port A to port B, and then flows to the brake
wheel cylinder.
When the brake pedal is released, brake fluid returns
from the brake wheel cylinder to the master cylinder
through port B to port A and No. 1 Check Valve.

Condition of Actuator
Part Name
Signal from
ABS ECUOperation
Pressure
Holding ValveOFFPort AOpen
Pressure
Reduction
Valve
OFFPort BClosed
Pump MotorOFFRotating

Hydraulic Circuit
ii) During Emergency Braking (ABS Activated)
 Pressure Reduction Mode
When the wheel about to lock , the control signal from
the ECU causes port A to close and port D to open,
thus engaging the pressure reduction mode.
At this time the brake fluid flows from the wheel
cylinder, through ports C and D, to the reservoir
reducing the wheel pressure.
At the same time the brake fluid is pumped and
returned to the master cylinder.

Condition of Actuator
Part Name
Signal from
ABS ECUOperation
Pressure
Holding ValveONPort AClosed
Pressure
Reduction
Valve
ONPort DOpen
Pump MotorONRotating

Hydraulic Circuit