fuel cap TOYOTA SUPRA 1997 Service Repair Manual
[x] Cancel search | Manufacturer: TOYOTA, Model Year: 1997, Model line: SUPRA, Model: TOYOTA SUPRA 1997Pages: 1807, PDF Size: 39.36 MB
Page 105 of 1807
124APPENDIXÐSUPRA
SUPRA
Item AreaU.S.A..Body Type2±Door Liftback (Standard Roof)2±Door Liftback (Sport Roof)Vehicle GradeÐModel CodeJZA80L±ALMVFAJZA80L±ALPVFAJZA80L±AJMVFAJZA80L±AJPVFALength mm (in.)4515 (177.8)uuu
OverallWidth mm (in.)1810 (71.3)uuuOverallHeight* mm (in.)1275 (50.2)uuuWheel Base mm (in.)2550 (100.4)uuu
TreadFront mm (in.)1520 (59.8)uuuTreadRear mm (in.)1525 (60.0)uuu
Effective Head RoomFront mm (in.)953.2 (37.5)u946.8 (37.3)uEffective Head RoomRear mm (in.)834.5 (32.9)uuu
sEffective Leg RoomFront mm (in.)1117.0 (44.0)uuu
ghtsEffective Leg RoomRear mm (in.)605.1 (23.8)uuu
We i g
h
Shoulder RoomFront mm (in.)1376.3 (54.2)uuu
icle WShoulder RoomRear mm (in.)1113.2 (43.8)uuu
VehicOverhangFront mm (in.)950 (37.4)uuu
s & VeOverhangRear mm (in.)1015 (40.0)uuu
sions
&Min. Running Ground Clearance mm (in.)120 (4.7)uuu
mensioAngle of Approach degrees13uuu
DimeAngle of Departure degrees17uuu
ajor DFront kg (lb)762 (1680)778 (1715)773 (1705)789 (1740)MajoCurb WeightRear kg (lb)694 (1530)703 (1550)710 (1565)719 (1585)MCurb WeightTotal kg (lb)1456 (3210)1481 (3265)1483 (3270)1508 (3325)Front kg (lb)937 (2065)uuuGross Vehicle WeightRear kg (lb)1002 (2210)uuuGross Vehicle WeightTotal kg (lb)1939 (4275)uuuFuel Tank Capacity l (U.S. gal., Imp. gal.)70 (18.5, 15.4)uuuLuggage Compartment Capacity m3 (cu. ft.)ÐÐÐÐMax. Speed km/h (mph)240 (150)uuuMax. Cruising Speed km/h (mph)193 (120)uuu
Acceleration0 to 100 km/h sec.6.87.46.87.4
ceAcceleration0 to 400 m sec.15.215.715.215.7
mance1st Gear km/h (mph)54 (34)61 (38)54 (34)61 (38)
rform
a
Max Permissible Speed2nd Gear km/h (mph)94 (58)112 (70)94 (58)112 (70)PerfoMax. Permissible Speed3rd Gear km/h (mph)139 (86)Ð139 (86)ÐP4the Gear km/h (mph)ÐÐÐÐTurning DiameterWall to Wall m (ft.)11.5 (38)uuuTurning Diameter(Outside Front)Curb to Curb m (ft.)10.9 (36)uuuEngine Type2JZ±GEuuuValve Mechanism24±Valve, DOHCuuuBore x Stroke mm (in.)86.0 x 86.0 (3.39 x 3.39)uuu
eDisplacement cm3 (cu. in..)2997 (182.9)uuu
ngineCompression Ratio10.0 : 1uuuEngCarburetor TypeSFIuuuResearch Octane No. RON96uuuMax. Output (SAE±NET) kW/rpm (HP @ rpm)164/5800 (220 @ 5800)uuuMax. Torque (SAE±NET) N.m/rpm (lb±ft @ rpm)285/4800 (210 @ 4800)uuu
alBattery Capacity (20HR) Voltage & Amp. hr.12±52uuu
ginectric a lGenerator Output Watts1080uuuEnginElectrStarter Output kW1.4uuuClutch TypeDry, Single PlateÐDry, Single PlateÐTransmission TypeW58A340EW58A340EIn First3.2852.8043.2852.804In Second1.8941.5311.8941.531In Third1.2751.0001.2751.000Transmission Gear RatioIn Fourth1.0000.7051.0000.705Transmission Gear RatioIn Fifth0.783Ð0.783ÐIn SixthÐÐÐÐIn Reverse3.7682.3933.7682.393Differential Gear Ratio4.083uuuDifferential Gear Size mm (in.)205 (8.07)uuu
ssisBrake TypeFrontVentilated Discuuu
ChassBrake TypeRearVentilated DiscuuuChParking Brake TypeDual±ServouuuBrake Booster Type and Style in.Tandem 8º + 9ºuuuProportioning Valve TypeP & B Valveuuu
Suspension TypeFrontDouble WishboneuuuSuspension TypeRearDouble Wishboneuuu
Stabilizer BarFrontSTDuuuStabilizer BarRearSTDuuuSteering Gear TypeRack & PinionuuuSteering Gear Ratio (Overall)17.5 : 1uuuPower Steering TypeIntegral Typeuuu* : Unladen Vehicle, *1 : Electrically Controlled Transmission with an intelligent sporty control
Page 201 of 1807
N08911
B
AC
N08959
F
1/2
E
Z09401
Ignition
Switch
BatteryWarning Light
N08933
N08993
- BODY ELECTRICALCOMBINATION METER
BE-45
2023 Author: Date:
1997 SUPRA (RM502U)
6. INSPECT FUEL RECEIVER GAUGE RESISTANCE
Measure the resistance between terminals.
Between terminalsResistance (W)
A - BApprox. 269.7
A - CApprox. 123.5
B - CApprox. 146.2
If resistance value is not as specified, replace the fuel receiver
gauge.
7. INSPECT FUEL SENDER GAUGE RESISTANCE
Measure the resistance between terminals 2 and 3 for each
float position.
Float position: mm (in.)Resistance (W)
F: Approx. 33.8 (1.331)Approx. 4.0
1/2: Approx. 44.8 (1.764)Approx. 55.0
E: Approx. 141.1 (5.555)Approx. 107.0
If resistance value is not as specified, replace the sender
gauge.
8. INSPECT FUEL LEVEL WARNING LIGHT
(a) Disconnect the connector from the sender gauge.
(b) Connect terminals 1 and 3 on the wire harness side con-
nector.
(c) Turn the ignition switch ON, check that the warning light
lights up.
If the warning light does not light up, test the bulb or inspect wire
harness.
9. INSPECT FUEL LEVEL WARNING SWITCH OPERA-
TION
(a) Apply battery positive voltage between terminals 1 and 3
through a 3.4 W test bulb, check that the bulb lights up.
HINT:
It will take a short time for the bulb to light up.
(b) Submerge the switch in fuel, check that the bulb goes out.
If operation is not as specified, replace the sender gauge.
Page 378 of 1807
GENERAL REPAIR INSTRUCTIONS
Work Precautions
VEHICLE PROTECTION
When welding, protect the
painted surfaces, windows,
seats an carpet with heat-
resistant, fire-proof covers.SAFETY
1. Before performing repair work, check
for fuel leaks. If a leak is found, be
sure to close the opening totally.
2. If it is necessary to use a frame in the
area of the-fuel tank, first remove the
tank and plug the fuel line. SAFETY
Never stand in direct line
with the chain when using
a puller on the body or
frame, and be sure to
attach a safety cable.
WRONG
Glass Cover
Safety Cable
Seat Cover
WRONG
HAND TOOLS
keeping your hand tools
in neat order improve
your work efficiency. SAFETY WORK CLOTHES
In addition to the usual mechanic's wear, cap and safety shoes,
the appropriate gloves, head protector, glasses, ear plugs, face
protector, dust-prevention mask, etc. should be worn as the
situation demands.
Dust-
Prevention
Mask.Welder's
Glasses
Ear
Plugs
Body
Mechanic
Stand Face
Protector
Head
Protector
Eye
Protector
Welder's
Gloves Safety
Shoes
INTRODUCTIONIN-10
Page 1016 of 1807
17
E GLOSSARY OF TERMS AND SYMBOLS
METER, ANALOG
Current flow activates a magnetic
coil which causes a needle to
move, thereby providing a relative
display against a background
calibration. LED (LIGHT EMITTING DIODE)
Upon current flow, these diodes
emit light without producing the
heat of a comparable light. IGNITION COIL
Convert low-voltage DC current
into high-voltage ingition current
for firing the spark plugs.
1. SINGLE
FILAMENT
GROUND
The point at which wiring attaches
to the Body, thereby providing a
return path for an electrical circuit;
without a ground, current cannot
flow.
Current flow causes a headlight
filament to heat up and emit light.
A headlight may have either a
single (1) filament or a double (2)
filament. BATTERY
Stores chemical energy and
converts it into electrical energy.
Provides DC current for the
auto's various electrical circuits.
CAPACITOR (Condenser)
A small holding unit for temporary
storage of electrical voltage.
CIRCUIT BREAKER
Basically a reusable fuse, a circuit
breaker will heat and open if too
much current flows through it.
Some units automatically reset when
cool, others must be manually reset.
DIODE
A semiconductor which allows
current flow in only one direction.
DIODE, ZENER
A diode which allows current
flow in one direction but blocks
reverse flow only up to a specific
voltage. Above that potential, it
passes the excess voltage.
This acts as a simple voltage
regulator.
PHOTODIODE
The photodiode is a
semiconductor which controls the
current flow according to the
amount of light.
FUSE
A thin metal strip which burns
through when too much current
flows through it, thereby stop-
ping current flow and protecting a
circuit from damage.
FUSIBLE LINK
A heavy-gauge wire placed in
high amperage circuits which
burns through on overloads,
thereby protecting the circuit.
The numbers indicate the cross-
section surface area of the wires.HORN
An electric device which sounds a
loud audible signal.
LIGHT
Current flow through a filament
causes the filament to heat up
and emit light.
METER, DIGITAL
Current flow activates one or
many LED's, LCD's, or fluoresent
displays, which provide a relative
or digital display.
MOTOR
A power unit which converts
electrical energy into mechanical
energy, especially rotary motion. CIGARETTE LIGHTER
An electric resistance heating
element.
DISTRIBUTOR, IIA
Channels high-voltage current
from the ignition coil to the
individual spark plugs.
2. DOUBLE
FILAMENT
HEADLIGHTS
FUEL
M
(for High Current Fuse or
Fusible Link.)
(for Medium Current Fuse)
Page 1273 of 1807
B02438
EC046-01
EC3069Check Valve (Vacuum Valve)Gasket
P12150
P12175
Z16768
Port C
Compressed
Air
Air AirAir
- EMISSION CONTROL (2JZ-GTE)EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM
EC-5
1242 Author: Date:
1997 SUPRA (RM502U)
EVAPORATIVE EMISSION (EVAP)
CONTROL SYSTEM
INSPECTION
1. VISUALLY INSPECT LINES AND CONNECTIONS
Look for loose connections, sharp bends or damage.
2. VISUALLY INSPECT FUEL TANK
Look for deformation, cracks or fuel leakage.
3. VISUALLY INSPECT FUEL TANK CAP
Check if the cap and/or gasket are deformed or damaged.
If necessary, repair or replace the cap.
4. REMOVE CHARCOAL CANISTER
5. VISUALLY INSPECT CHARCOAL CANISTER
Look for cracks or damage.
6. CHECK FOR CLOGGED FILTER AND STUCK CHECK
VA LV E
(a) Using low pressure compressed air (4.71 kPa (48 gf/cm
2,
0.68 psi)), blow into port C and check that air flows without
resistance from the other ports.
Page 1284 of 1807
S05506
Sub-Throttle Position
Sensor Connector
Water Bypass Hose
PS Air Hose
Gasket
Throttle Body
Throttle Position Sensor Connector
Sub-Throttle Actuator Connector
Control Cable
Bracket and Cable
Vacuum
Hose
Air
Hose
IAC Valve Pipe
Air Hose
Air Intake
Chamber Stay
IAC Valve
Connector Engine Wire Protector
VSV Connector for EGR
MAP Sensor Connector
VSV Connector for Fuel Pressure Control
Filler Cap
x 10 No.3 Timing Belt Cover
Ignition Coils AssemblyEVAP Hose
EGR Pipe
Engine Wire
Protector
Ground Cable
Brake Booster
Vacuum Hose
EGR Gas
Temperature
Sensor Connector
Vacuum Hose
Pressure Tank
and VSV Assembly
Engine Wire Bracket
Engine Wire Clamp
Manifold Stay Gasket
x 5
No.4 Water Bypass Pipe PS Air Hose
No.4 Water
Bypass Hose
Water Bypass hose
Air Intake Chamber
Engine Wire Protector
Gasket
Fuel Inlet Pipe
Fuel Pressure
Pulsation DamperVacuum Sensing Hose
Intake Manifold and
Delivery Pipe Assembly
Fuel Return Hose
Gasket
x 6
Gasket Gasket
Engine Wire Bracket
PS Vane Pump
Oil Dipstick and
Guide for Transmission Oil Dipstick and
Guide for Engine
O-Ring
O-Ring
Timing Belt
Gasket
No.2 Timing
Belt Cover
Drive Belt Tensioner
Dust Cover
Timing Belt Tensioner
Drive Belt Tensioner Damper
Non-reusable part
Drive Belt TensionerM/T
- ENGINE MECHANICAL (2JZ-GTE)CYLINDER HEAD
EM-27
1132 Author: Date:
1997 SUPRA (RM502U)
Page 1311 of 1807
P11919
P11910
Starter
WireDisconnect
P11643
Fuel Inlet Hose
P12534Fuel Return Hose
P11642
(2)
(1)
- ENGINE MECHANICAL (2JZ-GTE)ENGINE UNIT
EM-59
1164 Author: Date:
1997 SUPRA (RM502U)
(c) Disconnect the connector from the engine room main
wire.
(d) Disconnect the engine wire from the 2 wire clamps.
(e) Remove the rubber cap and nut, and disconnect the gen-
erator wire.
(f) Disconnect the wire clamp and PS solenoid valve con-
nector.
(g) Remove the bolt and disconnect the ground strap from
the cylinder block.
(h) Disconnect the starter wire from the LH engine mounting
bracket.
(i) Remove the rubber cap and nut, and disconnect the start-
er wire.
15. DISCONNECT FUEL HOSES
(a) Remove the union bolt and 2 gaskets, and disconnect the
fuel inlet hose.
HINT:
Put a suitable container or shop rag under the fuel pipe
support.
Slowly loosen the union bolt.
(b) Suspend the hose union end upward.
(c) Disconnect the fuel return hose from the clamp of the dip-
stick guide.
(d) Disconnect the fuel return hose from the fuel return pipe.
Plug the hose end.
16. DISCONNECT PS PUMP WITHOUT
DISCONNECTING HOSES
(a) Disconnect these hoses:
(1) PS air hose from throttle body
(2) PS air hose from air intake chamber
(b) Remove the 2 bolts, and disconnect the vane pump from
the pump bracket.
HINT:
Put aside the vane pump, and suspend it securely.
(c) Remove the 3 bolts and pump bracket.
Page 1322 of 1807
EM0AN-03
S00635
Piston Ring (No.1 Compression)
Piston Ring (Side Rail and Expander)
Snap RingPiston Ring (No.2 Compression)
Snap RingPistonPiston Pin
Connecting Rod Bushing
Connecting Rod
Connecting Rod Bearing
Connecting
Rod Cap
No.2 Water Bypass
Pipe with Hose
Gasket
x 8
Flywheel (M/T)
Engine Coolant Drain Plug
Rear Oil Seal
Retainer
Oil Seal
x 6x 8
Front Spacer
Rear Plate
Drive Plate (A/T)
Crankshaft Position Sensor
Cylinder Block O-Ring
Water Pump
x 6
Generator
Crankshaft
Front Oil Sealx 9 Oil Pump
Idler Pulley
O-RingKnock Sensor 2
Fuel Pipe Supportx 6
Oil Nozzle
Knock
Sensor 1
LH Engine Mounting
Bracket and
Insulator Assembly
Crankshaft
O-Ring
Oil Cooler
Oil Filter Gasket O-Ring
Oil Filter Bracket
O-RingMain Bearing
Crankshaft Thrust
Washer
Main Bearing Cap
Turbo Oil
Outlet Pipe
Gasket
No.1 Oil Pan
Gasket
x 16x 6
x 5
x 14
GasketRH Engine Mounting
Bracket and Insulator
Assembly
Oil Level Sensor
Oil Strainer
No.2 Oil Pan
Drain Plug
Non-reusable part
Precoated part
Gasket
EM-70
- ENGINE MECHANICAL (2JZ-GTE)CYLINDER BLOCK
1175 Author: Date:
1997 SUPRA (RM502U)
CYLINDER BLOCK
COMPONENTS
Page 1323 of 1807
EM0AO-02
P02447
P04467
P12207Knock Sensor
Union for Oil Cooler HoseOil Pressure
Switch
SST
- ENGINE MECHANICAL (2JZ-GTE)CYLINDER BLOCK
EM-71
1176 Author: Date:
1997 SUPRA (RM502U)
DISASSEMBLY
1. M/T:
REMOVE FLYWHEEL
2. A/T:
REMOVE DRIVE PLATE
3. INSTALL ENGINE TO ENGINE STAND FOR
DISASSEMBLY
4. REMOVE GENERATOR
5. REMOVE TIMING BELT AND PULLEYS
(See page EM-15)
6. REMOVE CYLINDER HEAD (See page EM-29)
7. REMOVE OIL COOLER (See page LU-20)
8. REMOVE NO.2 WATER BYPASS PIPE WITH HOSE
Remove the 2 bolts, 2 nuts, water bypass pipe and gasket.
9. REMOVE KNOCK SENSORS
Using SST, remove the switch and sensors.
SST 09816-30010
10. REMOVE OIL FILTER BRACKET
Remove the union bolt, gasket, oil filter bracket and O-ring.
11. REMOVE LH ENGINE MOUNTING BRACKET AND IN-
SULATOR ASSEMBLY
12. REMOVE FUEL PIPE SUPPORT
13. REMOVE OIL PRESSURE SWITCH AND KNOCK SEN-
SORS
(a) Using SST, remove the switch and sensors.
SST 09816-30010
(b) Remove the union nut and gasket.
14. REMOVE UNION FOR OIL COOLER HOSE
15. REMOVE ENGINE COOLANT DRAIN PLUG
16. REMOVE RH ENGINE MOUNTING BRACKET AND IN-
SULATOR ASSEMBLY
17. REMOVE CRANKSHAFT POSITION SENSOR
18. REMOVE WATER PUMP (See page CO-7)
19. REMOVE OIL PUMP (See page LU-9)
20. REMOVE REAR OIL SEAL RETAINER
(a) Remove the 6 bolts.
(b) Remove the oil seal retainer by prying the area between
the oil seal retainer and main bearing cap with a screw-
driver.
21. CHECK CONNECTING ROD THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while mov-
ing the connecting rods back and forth.
Standard thrust clearance:
0.250 - 0.402 mm (0.0098 - 0.0158 in.)
Maximum thrust clearance:
0.50 mm (0.0197 in.)
If the thrust clearance is greater than maximum, replace the
connecting rod assembly(s). If necessary, replace the crank-
shaft.
Page 1427 of 1807
MA0688
MA01G-01
- MAINTENANCEENGINE
MA-5
42 Author: Date:
1997 SUPRA (RM502U)
ENGINE
INSPECTION
1. REPLACE TIMING BELT
(2JZ-GE: See page EM-17)
(2JZ-GTE: See page EM-19)
2. INSPECT DRIVE BELT
(See page CH-2)
3. REPLACE SPARK PLUGS
(2JZ-GE: See page IG-1)
(2JZ-GTE: See page IG-1)
4. INSPECT AIR FILTER
(a) Remove the air filter.
(b) Visually check that the air filter is not excessively dam-
aged or oily.
If necessary, replace the air filter.
(c) Clean the filter with compressed air.
First blow from the inside thoroughly, then blow off the
outside of the filter.
(d) Reinstall the air filter and air cleaner case.
5. REPLACE AIR FILTER
Replace the air filter with a new one.
6. REPLACE ENGINE OIL AND OIL FILTER
(See page LU-4)
7. REPLACE ENGINE COOLANT
(See page CO-2)
8. INSPECT CHARCOAL CANISTER
(2JZ-GE: See page EC-5)
(2JZ-GTE: See page EC-5)
9. REPLACE GASKET IN FUEL TANK CAP
(2JZ-GE: See page EC-5)
(2JZ-GTE: See page EC-5)
10. INSPECT FUEL LINES AND CONNECTIONS
(2JZ-GE: See page SF-32)
(2JZ-GTE: See page SF-34)
11. INSPECT EXHAUST PIPES AND MOUNTINGS
Visually check the pipes, hangers and connections for severe
corrosion, leaks or damages.
12. ADJUST VALVE CLEARANCE
(2JZ-GE: See page EM-4)
(2JZ-GTE: See page EM-4)