length TOYOTA SUPRA 1997 Service Repair Manual
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Page 11 of 1807
Q04326
Matchmarks
Secondary
FlywheelPrimary
Flywheel
Q04327
Matchmarks CL-24
- CLUTCHCLUTCH UNIT (2JZ-GTE)
1565 Author: Date:
1997 SUPRA (RM502U)
8. INSPECT FLYWHEEL DAMPER FOR GREASE LEAK-
AGE
If grease has sprayed onto the clutch housing, replace the fly-
wheel assembly.
9. INSPECT FLYWHEEL DAMPER ROTATIONAL FREE-
PLAY
(a) Install the 2 bolts to the secondary flywheel at diametrical-
ly opposite positions.
(b) Holding both the bolts, and turn the secondary flywheel
clockwise until it stops.
(c) Put matchmarks on the primary and secondary flywheels
at this position.
(d) Then rotate the primary flywheel counterclockwise by
hand until it stops.
(e) Put matchmarks on the primary flywheel at this position.
(f) Measure the circumferential length between the 2 match-
marks on the secondary flywheel.
Standard: 105 mm (4.134 in.)
(g) Repeat the previous steps (d) to (f) 4 times and if the mea-
surement is greater than the maximum length replace the
flywheel assembly (See page EM-88).
Page 34 of 1807
R06864
SST
- PROPELLER SHAFTPROPELLER SHAFT ASSEMBLY
PR-13
1686 Author: Date:
1997 SUPRA (RM502U)
(h) Using SST, torque the adjust nut.
SST 09922-10010
Torque: 50 N´m (515 kgf´cm, 37 ft´lbf)
HINT:
Use torque wrench with a fulcrum length of 34.5 cm (13.6 in.).
3. ADJUST PROPELLER SHAFT JOINT ANGEL (See
page PR-14)
NOTICE:
The joint angle should be checked when the propeller shaft
is removed and installed.
4. NORMAL ROOF:
INSTALL CENTER FLOOR CROSSMEMBER BRACE
Install the center floor crossmember brace and 4 bolts.
Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)
5. SPORT ROOF:
INSTALL CENTER FLOOR CROSSMEMBER BRACE
Install the center floor crossmember brace and 6 bolts.
Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)
6. INSTALL HEAT INSULATOR
Install the heat insulator and torque the 4 nuts.
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
7. INSTALL EXHAUST PIPE (See page EM-94)
8. INSTALL OXYGEN SENSOR
Install the oxygen sensor with heat insulator and torque the 2
nuts.
Torque: 44 N´m (450 kgf´cm, 34 in.´lbf)
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 250 of 1807
I01413
CONTINUED FROM PREVIOUS PAGE
Is power source from radio OK?Check continuity between motor antenna
and radio receiver assembly.
Wire harness faulty.
Radio receiver assembly faulty. Inspect motor.
Motor antenna control relay faulty.
Motor faulty.No
Ye s
No
No
Ye sYe s
I01414
27
Antenna ANTENNA-RELA TED
Is the antenna cable connected securely to the radio?Connect the cable
Go to 26. No
Ye s
Normal Type
Does antenna rod extend fully when radio
Variable Length Type
Does antenna rod extend to the specified
radio switch is turned off?
Inspect glass printed antenna.
(w/ glass printed antenna)Glass printed antenna faulty. NG
OK
Is the antenna nut tight?
Temporarily install another antenna. Functions OK?
Radio receiver side faulty.Tighten nut.
Motor antenna faulty. switch is turned on?
Does antenna rod fully retract when the length when the radio switch is turned on.No
No Ye s
Ye s
Ye sYe s BE-94
- BODY ELECTRICALAUDIO SYSTEM
2072 Author: Date:
1997 SUPRA (RM502U)
Page 321 of 1807
BO0RU-01
BO0632
BO0633
15°
45°
N10070
Full belt length minus
200 mm (7.87 in.) BO-68
- BODYSEAT BELT
2148 Author: Date:
1997 SUPRA (RM502U)
INSPECTION
CAUTION:
Replace the seat belt assembly (outer belt, inner belt, bolts
or nuts and sill-bar) if it has been used in a severe impact.
The entire assembly should be replaced even if damage is
not obvious.
Emergency Locking Retractor (ELR) and Automatic Lock-
ing Retractor (ALR) type
1. All seat belts:
RUNNING TEST (IN SAFE AREA)
(a) Fasten the front seat belts.
(b) Drive the car at 10 mph (16 km/h) and make a very hard
stop.
Check that the belt locks and cannot be extended at this
time.
HINT:
Conduct this test in a safe area. If the belt does not lock, remove
the belt mechanism assembly and conduct the following static
check. Also, whenever installing a new belt assembly, verify the
proper operation before installation.
2. Driver 's seat belt (ELR):
STATIC TEST
(a) Make sure that the belt locks when pulled out quickly.
(b) Remove the locking retractor assembly.
(c) Tilt the retractor slowly.
(d) Make sure that the belt can be pulled out at a tilt of 15 de-
grees or less, and cannot be pulled out over 45 degrees
of tilt.
If a problem is found, replace the assembly.
3. Except driver's seat belt (ALR/ ELR):
STATIC TEST
(a) Make sure that the belt locks when pulled out quickly.
(b) Remove the locking retractor assembly.
(c) Pull out the whole belt and measure the length of the
whole belt.
Then retract the belt slightly and pull it out again.
(d) Make sure that the belt cannot be extended further.
If a problem is found, replace the assembly.
(e) Retract the whole belt, then pull out the belt until 200 mm
(7.87 in.) of belt remains retracted.
(f) Tilt the retractor slowly.
(g) Make sure that the belt can be pulled out at a tilt of 15 de-
grees or less, and cannot be pulled out at over 45 degrees
of tilt.
If a problem is found, replace the assembly.
Page 335 of 1807
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)
Page 338 of 1807
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)
Page 1290 of 1807
EM2534
Overall Length
EM0255
P02127
45°
Carbide
Cutter
Z00373
Width
P03966
45°
15°
Width EM-38
- ENGINE MECHANICAL (2JZ-GTE)CYLINDER HEAD
1143 Author: Date:
1997 SUPRA (RM502U)
(d) Check the valve overall length.
Standard overall length:
Intake 98.29 - 98.79 mm (3.8697 - 3.8894 in.)
Exhaust 98.84 - 99.34 mm (3.8913 - 3.9110 in.)
Minimum overall length:
Intake 98.19 mm (3.8657 in.)
Exhaust 98.74 mm (3.8874 in.)
If the overall length is less than minimum, replace the valve.
(e) Check the surface of the valve stem tip for wear.
If the valve stem tip is worn, resurface the tip with a grinder or
replace the valve.
NOTICE:
Do not grind off more than the minimum overall length.
11. INSPECT AND CLEAN VALVE SEATS
(a) Using a 45° carbide cutter, resurface the valve seats.
Remove only enough metal to clean the seats.
(b) Check the valve seating position.
Apply a thin coat of prussian blue (or white lead) to the
valve face. Lightly press the valve against the seat. Do not
rotate the valve.
(c) Check the valve face and seat for the following:
If blue appears 360° around the face, the valve is
concentric. If not, replace the valve.
If blue appears 360° around the valve seat, the
guide and face are concentric. If not, resurface the
seat.
Check that the seat contact is in the middle of the
valve face with the following width:
Intake 1.0 - 1.4 mm (0.039 - 0.055 in.)
Exhaust 1.2 - 1.6 mm (0.047 - 0.063 in.)
If not, correct the valve seats as follows:
If the seating is too high on the valve face, use 15°
and 45° cutters to correct the seat.
Page 1291 of 1807
Z02456
45° 75°
Width
P02126
Z02457
Deviation
EM0801
EM0281
- ENGINE MECHANICAL (2JZ-GTE)CYLINDER HEAD
EM-39
1144 Author: Date:
1997 SUPRA (RM502U)
If the seating is too low on the valve face, use 75°
and 45° cutters to correct the seat.
(d) Hand-lap the valve and valve seat with an abrasive com-
pound.
(e) After hand-lapping, clean the valve and valve seat.
12. INSPECT VALVE SPRINGS
(a) Using a steel square, measure the deviation of the valve
spring.
Maximum deviation: 2.0 mm (0.079 in.)
If deviation is greater than maximum, replace the valve spring.
(b) Using vernier calipers, measure the free length of the
valve spring.
Free length: 41.70 mm (1.6417 in.)
If the free length is not as specified, replace the valve spring.
(c) Using a spring tester, measure the tension of the valve
spring at the specified installed length.
Installed tension:
186 - 206 N (19.0 - 21.0 kgf, 42 - 46 lbf)
at 34.5 mm (1.358 in.)
If the installed tension is not as specified, replace the valve
spring.
Page 1371 of 1807
LU0JZ-01
P12280
P12205
SST
Z04118
LU-4
- LUBRICATIONOIL AND FILTER
1451 Author: Date:
1997 SUPRA (RM502U)
REPLACEMENT
CAUTION:
Prolonged and repeated contact with mineral oil will
result in the removal of natural fats from the skin,
leading to dryness, irritation and dermatitis. In addi-
tion, used engine oil contains potentially harmful
contaminants which may cause skin cancer.
Exercise caution in order to minimize the length and
frequency of contact of your skin to used oil. Wear
protective clothing and gloves. Wash your skin thor-
oughly with soap and water, or use water-less hand
cleaner, to remove any used engine oil. Do not use
gasoline, thinners, or solvents.
In order to preserve the environment, used oil and
used oil filters must be disposed of only at desig-
nated disposal sites.
1. DRAIN ENGINE OIL
(a) Remove the oil filler cap.
(b) Remove the oil drain plug, and drain the oil into a contain-
er.
2. REPLACE OIL FILTER
(a) Using SST, remove the oil filter.
SST 09228-07501
(b) Check and clean the oil filter installation surface.
(c) Apply clean engine oil to the gasket of a new oil filter.