check engine TOYOTA SUPRA 1997 Service Repair Manual
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Page 1 of 1807
CL03Y-02
- CLUTCHTROUBLESHOOTING
CL-1
1542 Author: Date:
1997 SUPRA (RM502U)
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
Clutch grabs/chatters
1. Engine mounting (Loosen)
2. Clutch disc (Runout is excessive)
3. Clutch disc (Oily)
4. Clutch disc (Worn out)
5. Clutch disc (Damaged torsion rubber)
6. Clutch disc (Glazed)
7. Diaphragm spring (Out of tip alignment)-
CL-15
CL-20
CL-15
CL-20
CL-15
CL-20
CL-15
CL-20
CL-15
CL-20
CL-19
CL-25
Clutch pedal spongy
1. Clutch line (Air in line)
2. Master cylinder cup (Damaged)
3. Release cylinder cup (Damaged)-
CL-5
CL-10
Clutch noisy
1. Release bearing (Worn, dirty or damaged)
2. Pilot bearing (Worn or damaged)
3. Input shaft bearing (Worn, dirty or damaged)
4. Clutch disc torsion rubber (Damaged)CL-15
CL-20
CL-15
CL-20
-
CL-15
CL-20
Page 15 of 1807
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.
Page 16 of 1807
Q04185
Clutch Start Switch
Q00617
8 ± 0.5 mm
(0.31 ± 0.020 in.) CL-4
- CLUTCHCLUTCH PEDAL
1545 Author: Date:
1997 SUPRA (RM502U)
Standard distance: 25 mm (0.98 in.) or more
(From pedal stroke end position to release point)
If the distance is not as specified, do the following operation.
Inspect pedal height.
Inspect push rod play and pedal freeplay.
Bleed the clutch line.
Inspect the clutch cover and disc.
7. CHECK CLUTCH START SYSTEM
(a) Check that the engine does not start when the clutch ped-
al is released.
(b) Check that the engine starts when the clutch pedal is fully
depressed.
If necessary, adjust or replace the clutch start switch.
8. INSPECT CONTINUITY OF CLUTCH START SWITCH
(a) Check that there is continuity between the terminals when
the switch is ON (pushed).
(b) Check that there is no continuity between the terminals
when the switch is OFF (free).
If continuity is not as specified, replace the switch.
Page 53 of 1807
IN0253
WRONG CORRECT
IN0252
WRONG CORRECT
IN0002
Example IN-6
- INTRODUCTIONREPAIR INSTRUCTIONS
6 Author: Date:
1997 SUPRA (RM502U)
(l) Observe the following precautions to avoid damage to the
following parts:
(1) Do not open the cover or case of the ECU, ECM,
PCM or TCM unless absolutely necessary. (If the IC
terminals are touched, the IC may be destroyed by
static electricity.)
(2) To disconnect vacuum hoses, pull on the end, not
the middle of the hose.
(3) To pull apart electrical connectors, pull on the con-
nector itself, not the wires.
(4) Be careful not to drop electrical components, such
as sensors or relays. If they are dropped on a hard
floor, they should be replaced and not reused.
(5) When steam cleaning an engine, protect the elec-
tronic components, air filter and emissions-related
components from water.
(6) Never use an impact wrench to remove or install
temperature switches or temperature sensors.
(7) When checking continuity at the wire connector, in-
sert the tester probe carefully to prevent terminals
from bending.
(8) When using a vacuum gauge, never force the hose
onto a connector that is too large. Use a step-down
adapter for adjustment. Once the hose has been
stretched, it may leak.
(m) Tag hoses before disconnecting them:
(1) When disconnecting vacuum hoses, use tags to
identify how they should be reconnected.
(2) After completing a job, double check that the vacu-
um hoses are properly connected. A label under the
hood shows the proper layout.
(n) Unless otherwise stated, all resistance is measured at an
ambient temperature of 20°C (68°F). Because the resis-
tance may be outside specifications if measured at high
temperatures immediately after the vehicle has been run-
ning, measurements should be made when the engine
has cooled down.
Page 62 of 1807
B02572
TRAC OFF
Indicator Light
TRAC Cut
Switch
N19405
- INTRODUCTIONFOR ALL OF VEHICLES
IN-15
15 Author: Date:
1997 SUPRA (RM502U)
(c) Install the antenna feeder at least 20 cm (7.87 in.) away from the ECU and sensors of the vehicle's
electronics systems. For details about ECU and sensors locations, refer to the section on the applica-
ble component.
(d) Do not wind the antenna feeder together with the other wiring. As much as possible, also avoid running
the antenna feeder parallel with other wire harnesses.
(e) Confirm that the antenna and feeder are correctly adjusted.
(f) Do not install powerful mobile communications system.
4. FOR USING OBDII SCAN TOOL OR TOYOTA HAND-HELD TESTER
Observe the following for safety reasons:
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.
Be sure to route all cables securely when driving with the OBDII scan tool or TOYOTA hand-held
tester connected to the vehicle. (i.e. Keep cables away from feet, pedals, steering wheel and shift
lever.)
Two persons are required when test driving with the OBDII scan tool or TOYOTA hand-held tes-
ter, one person to drive the vehicle and one person to operate the OBDII scan tool or TOYOTA
hand-held tester.
5. FOR VEHICLES EQUIPPED WITH TRACTION CON-
TROL (TRAC) SYSTEM
When using a 2 wheel drum tester such as a speedometer tes-
ter or chassis dynamometer, etc., or jacking up the rear wheels
and driving the wheels, always push in the TRAC cut (ºTRAC
OFFº) switch and turn the TRAC system OFF.
(a) Confirm TRAC system is OFF
(1) Press the TRAC cut (ºTRAC OFFº) switch.
(2) Check that the TRAC OFF indicator light comes on
when the TRAC system is turned off by the TRAC
cut switch.
HINT:
The TRAC OFF indicator light should always operate right after
the engine is restarted.
(3) Begin measurements.
Page 66 of 1807
Important Points in the Customer Problem Analysis
What ----- Vehicle model, system name
When ----- Date, time, occurrence frequency
Where ----- Road conditions
Under what conditions? ----- Running conditions, driving conditions, weather conditions
How did it happen? ----- Problem symptoms
(Sample) Engine control system check sheet.
ENGINE CONTROL SYSTEM Check Sheet
Customer's Name
Driver's Name
Data Vehicle
Brought in
License No.
Model and Model
Year
Frame No.
Engine Model
Odometer Reading
km
miles
Problem Symptoms
Engine does
not Start
Difficult to
Start
Poor Idling
Poor
Drive ability
Engine Stall
Others
Engine does not crankNo initial combustionNo complete combustion
Engine cranks slowly
Other
Incorrect first idleIdling rpm is abnormalHigh ( rpm)Low ( rpm)
Rough idling
Other
HesitationBack fireMuffler explosion (after-fire)Surging
Knocking
Other
Soon after startingAfter accelerator pedal depressed
After accelerator pedal released
During A/C operation
Shifting from N to D
Other
Datas Problem
ConstantSometimes ( times per day/month)
Inspector's
Name
CUSTOMER PROBLEM ANALYSIS CHECK
- INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMSIN-19
19 Author: Date:
1997 SUPRA (RM502U)
1. CUSTOMER PROBLEM ANALYSIS
In troubleshooting, the problem symptoms must be confirmed accurately and all preconceptions must be
cleared away in order to give an accurate judgment. To ascertain just what the problem symptoms are, it is
extremely important to ask the customer about the problem and the conditions at the time it occurred.
Important Point in the Problem Analysis:
The following 5 items are important points in the problem analysis. Past problems which are thought to be
unrelated and the repair history, etc. may also help in some cases, so as much information as possible should
be gathered and its relationship with the problem symptoms should be correctly ascertained for reference
in troubleshooting. A customer problem analysis table is provided in the troubleshooting section for each
system for your use.
Page 67 of 1807
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.
Page 69 of 1807
V07268
VIBRATION METHOD: When vibration seems to be the major cause.
CONNECTORS
WIRE HARNESS
PARTS AND SENSOR1
Slightly shake the connector vertically and horizontally.
Slightly shake the wire harness vertically and horizontally.
The connector joint, fulcrum of the vibration, and body
through portion are the major areas to be checked thorough-
ly.
Apply slight vibration with a finger to the part of the sensor
considered to be the problem cause and check if the
malfunction occurs.Shake Slightly
Swing Slightly
Vibrate Slightly
HINT: Applying strong vibration to relays may result in open
relays. IN-22
- INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
22 Author: Date:
1997 SUPRA (RM502U)
3. SYMPTOM SIMULATION
The most difficult case in troubleshooting is when there are no problem symptoms occurring. In such cases,
a thorough customer problem analysis must be carried out, then simulate the same or similar conditions and
environment in which the problem occurred in the customer's vehicle. No matter how much experience a
technician has, or how skilled he may be, if he proceeds to troubleshoot without confirming the problem
symptoms he will tend to overlook something important in the repair operation and make a wrong guess
somewhere, which will only lead to a standstill. For example, for a problem which only occurs when the en-
gine is cold, or for a problem which occurs due to vibration caused by the road during driving, etc., the prob-
lem can never be determined so long as the symptoms are confirmed with the engine hot condition or the
vehicle at a standstill. Since vibration, heat or water penetration (moisture) are likely causes for problems
which are difficult to reproduce, the symptom simulation tests introduced here are effective measures in that
the external causes are applied to the vehicle in a stopped condition.
Important Points in the Symptom Simulation Test:
In the symptom simulation test, the problem symptoms should of course be confirmed, but the problem area
or parts must also be found out. To do this, narrow down the possible problem circuits according to the symp-
toms before starting this test and connect a tester beforehand. After that, carry out the symptom simulation
test, judging whether the circuit being tested is defective or normal and also confirming the problem symp-
toms at the same time. Refer to the matrix chart of problem symptoms for each system to narrow down the
possible causes of the symptom.
Page 70 of 1807
V07469
HEAT METHOD: When the problem seems to occur when the suspect area is heated. 2
NOTICE:
(1) Do not heat to more than 60 °C (140 °F). (Temperature
is limited not to damage the components.)
(2) Do not apply heat directly to parts in the ECU.
3 WATER SPRINKLING METHOD:
NOTICE:
(1) Never sprinkle water directly into the engine
compartment, but indirectly change the temperature and
humidity by applying water spray onto the radiator front
surface.
(2) Never apply water directly onto the electronic
components.
4 OTHER: When a malfunction seems to occur when electrical load is excessive.When the malfunction seems to occur on a rainy day or in a
high-humidity condition. Heat the component that is the likely cause of the malfunction
with a hair dryer or similar object. Check to see if the malfunction
occurs.
Sprinkle water onto the vehicle and check to see if the malfunc-
tion occurs.
Turn on all electrical loads including the heater blower, head
lights, rear window defogger, etc. and check to see if the mal-
function occurs.ON (Service hint)
If a vehicle is subject to water leakage, the leaked water may
contaminate the ECU. When testing a vehicle with a water leak-
age problem, special caution must be taken.
Malfunc-
tion
- INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMSIN-23
23 Author: Date:
1997 SUPRA (RM502U)
Page 71 of 1807
DTC No.
Indicates the diagnostic trouble code.
Page or Instructions
Indicates the page where the inspection procedure
for each circuit is to be found, or gives instructions
for checking and repairs.
Detection Item
Indicates the system of the problem or
contents of the problem. Trouble Area
Indicates the suspect area of the
problem.
Mass Air Flow Circuit MalfunctionDetection Item
Open or short in mass air flow meter circuit
Mass air flow meter
ECM DTC No.
(See page)Trouble AreaMIL*MemoryP0100
(DI-23)
P0101
(DI-27)Mass Air Flow Circuit
Range/Performance Problem Mass air flow meter
P0115
(DI-32) Open or short in intake air temp. sensor circuit
Intake air temp. sensor
ECM Intake Air Temp. Circuit Malfunction P0110
(DI-28)
Engine Coolant Temp. Circuit
Range/Performance Problem Open or short in engine coolant temp. sensor circuit
Engine coolant temp. sensor
ECM
P0120
(DI-37)
Throttle/ Pedal Position Sensor/Switch
ºAº Circuit Range/Performance
P0116
(DI-36)
Throttle/Pedal Position Sensor/Switch
ºAº Circuit Malfunction
Insufficient Coolant Temp. for Closed Engine coolant temp. sensor
Cooling system Engine Coolant Temp. Circuit
Malfunction
Open or short in throttle position sensor circuit
Throttle position sensor
ECM
Throttle position sensor
Open or short in heated oxygen sensor circuit
Heated oxygen sensor
DTC CHART (SAE Controlled)
HINT: Parameters listed in the chart may not be exactly the same as your reading due to the type of instrument
or other factors.
If a malfunction code is displayed during the DTC check mode, check the circuit for that code listed in the table
below. For details of each code, turn to the page referred to under the ºSee pageº for the respective ºDTC No.º
in the DTC chart.
IN-24- INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
24 Author: Date:
1997 SUPRA (RM502U)
4. DIAGNOSTIC TROUBLE CODE CHART
The inspection procedure is shown in the table below. This table permits efficient and accurate troubleshoot-
ing using the diagnostic trouble codes displayed in the diagnostic trouble code check. Proceed with trouble-
shooting in accordance with the inspection procedure given in the diagnostic chart corresponding to the
diagnostic trouble codes displayed. The engine diagnostic trouble code chart is shown below as an example.