width TOYOTA SUPRA 1997 Service Repair Manual

Q04207
SST
Q04208
SST
Q04206
Q04203
B
A
Q04223
- CLUTCHCLUTCH UNIT (2JZ-GTE)
CL-23
1564 Author
: Date
:
1997 SUPRA (RM502U)
(b) Using SST, remove the pilot bearing.
SST 09303-3501 1
(c) Using SST and a hammer, drive in a new pilot bearing.
SST 09301-001 10
(d) Install 2 new bolts.
(e) First, torque the 2 bolts uniformly a little at a time.
Torque: 49 N´m (500 kgf´cm, 36 ft´lbf)
(f) Then tighten the 2 bolts an additional 80 - 100°.
6. INSPECT DIAPHRAGM SPRING FOR WEAR
Using calipers, measure the diaphragm spring for depth and
width of wear.
Maximum:
Depth A: 0.6 mm (0.024 in.)
Width B: 5.0 mm (0.197 in.)
If necessary, replace the clutch cover.
7. INSPECT RELEASE BEARING
Turn the bearing by hand while applying force in the axial direc-
tion.
HINT:
The bearing is permanently lubricated and requires no cleaning
or lubrication.
If a problem is found, replace the bearing together with the hub.

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

N09214
DLC3 DI-148
- DIAGNOSTICSENGINE (2JZ-GTE)
376 Author
: Date
:
1997 SUPRA (RM502U)
The 2 trip repeats the same mode a 2nd time. (However,
the IG switch must be turned OFF between the 1st trip and
2nd trip).
Freeze frame data:
Freeze frame data records the engine condition when a
misfire (DTC P0300 - P0306) or fuel trim malfunction
(DTC P0171, P0172), or other malfunction (first malfunc-
tion only), is detected.
Because freeze frame data records the engine conditions
(fuel system, calculator load, engine coolant tempera-
ture, fuel trim, engine speed, vehicle speed, etc.) when
the malfunction is detected, when troubleshooting it is
useful for determining whether the vehicle was running or
stopped, the engine warmed up or not, the air-fuel ratio
lean or rich, etc. at the time of the malfunction.
Priorities for Troubleshooting:
If troubleshooting priorities for multiple DTC are given in
the applicable diagnostic chart, these should be followed.
If no instructions are given troubleshoot DTC according
to the following priorities.
(1) DTC other than fuel trim malfunction (DTC P0171,
P0172), EGR (DTC P0401, P0402), and misfire
(DTC P0300 - 0306).
(2) Fuel trim malfunction (DTC P0171, P0172) and
EGR (DTC P0401, P0402).
(3) Misfire (DTC P0300 - P0306).
(b) Check the DLC3.
The vehicle's ECM uses V.P.W. (Variable Pulse Width) for
communication to comply with SAE J1850. The terminal
arrangement of DLC3 complies with SAE J1962 and
matches the V.P.W. format.
Terminal No.Connection / Voltage or ResistanceCondition
2Bus  Line / Pulse generationDuring transmission
4Chassis Ground / e Body Ground 1 W or lessAlways
5Signal Ground / e Body Ground 1 W or lessAlways
16Battery Positive / e Body Ground 9 - 14 VAlways
HINT:
If your display shows ºUNABLE TO CONNECT TO VEHICLEº
when you have connected the cable of the OBD II 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 ve-
hicle side or tool side.

If communication is normal when the tool is connected to
another vehicle, inspect DLC3 on the original vehicle.

If communication is still not possible when the tool is con-
nected to another vehicle, the problem is probably in the
tool itself, so consult the Service Department listed in the
tool's instruction manual.

S03235
Battery
B
R/B
No.22
2A
AM2
W-R W-R
IB147 6
Igniter
Switch
B-O
IJ11B-OB-OB-O B-O B-O
B-O
B-O
B-O
B-O
B-O
B-O
Spark Plug
Ignition Coil No.1
L-YG
Y
Y-B
Y-G
Y-R No.2
No.3
No.4
No.5
No.6 112
1
1
1
1
12
2
2
2
2
2
1
Noise Filter
BRECM
BR
EC
I24Igniter Tr
2
I22
6
5
4
10
11
12
I3 B
B
B
B
B
B
B
1
2
3
9
8
7
357
56
55
54
53
52
58
IGF5V IGT6 IGT5 IGT4IGT3 IGT2 IGT1
Tr1
5V
I3
I3
I3
I3
I3
I2 I3I3 I3 I3 I3I3
R-W
W-R
LG
B-R
L
R
R-Y DI-252
- DIAGNOSTICSENGINE (2JZ-GTE)
480 Author
: Date
:
1997 SUPRA (RM502U)
DTC P1300 Igniter Circuit Malfunction
CIRCUIT DESCRIPTION
The ECM determines the ignition timing, turns on Tr1 at a predetermined angle (°CA) before the desired
ignition timing and outputs an ignition signal (IGT) º1º to the igniter.
Since the width of the IGT signal is constant, the dwell angle control circuit in the igniter determines the time
the control circuit starts primary current flow to the ignition coil based on the engine rpm and ignition timing
one revolution ago, that is, the time the Tr2 turns on.
When it reaches the ignition timing, the ECM turns Tr1 off and outputs the IGT signal º0º.
This turns Tr2 off, interrupting the primary current flow and generating a high voltage in the secondary coil
which causes the spark plug to spark. Also, by the counter electromotive force generated when the primary
current is interrupted, the igniter sends an ignition confirmation signal (IGF) to the ECM.
The ECM stops fuel injection as a fail safe function when the IGF signal is not input to the ECM.
DTC No.DTC Detecting ConditionTrouble Area
P1300No IGF signal to ECM for 6 consecutive IGT signals during
engine running
Open or short in IGF or IGT circuit from igniter to ECM

Igniter

ECM
WIRING DIAGRAM
DI4TC-01

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.

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.

EM0AL-02
P0218510 mm Adhesive Width
2 - 3 mm
Adhesive
Z08040
Protrusion
P12307
(4) (3) (2) (1)
EM0645
Upward
Wide
Narrow
- ENGINE MECHANICAL (2JZ-GTE)CYLINDER HEAD
EM-45
1150 Author
: Date
:
1997 SUPRA (RM502U)
REASSEMBLY
HINT:

Thoroughly clean all parts to be assembled.

Before installing the parts, apply fresh engine oil to all slid-
ing and rotating surfaces.

Replace all gaskets and oil seals with new ones.
1. INSTALL HEATER UNION
HINT:
When using a new cylinder head, a new heater union must be
installed.
(a) Apply adhesive to the end of the heater union as shown
in the illustration.
Adhesive:
Part No. 08833-00070, THREE BOND 1324
or equivalent
(b) Using a wooden block and hammer, tap in a new heater
union, leaving standard position protruding from the cylin-
der head.
Standard protrusion:
48 mm (1.89 in.)
NOTICE:
Do not tap it in too far.
2. INSTALL VALVES
(a) Install a new oil seal on the valve guide bushing.
(b) Install these parts:
(1) Valve
(2) Spring seat
(3) Valve spring
(4) Spring retainer
NOTICE:
Confirm the correct direction of the valve spring.

P02171
Front MarkUpper Side
Rail
Lower Side
Rail No.1
Compression
No.2
Compression (Cavity)Expander
P02139
Z16762
5 mm
Hexagon
Wrench
P04797
20.0 mm
23.0 mmNo.1 Others
P04476
- ENGINE MECHANICAL (2JZ-GTE)CYLINDER BLOCK
EM-89
1194 Author
: Date
:
1997 SUPRA (RM502U)
(c) Position the piston rings so that the ring ends are as
shown.
NOTICE:
Do not align the piston ring ends.
3. INSTALL BEARINGS
(a) Align the bearing claw with the groove of the connecting
rod and connecting cap.
(b) Install the bearings in the connecting rod and connecting
rod cap.
NOTICE:
Apply a generous amount of oil on the sliding surface of the
bearing, and not on the back of it or on the surface to which
it is installed.
4. INSTALL OIL NOZZLES (WITH RELIEF VALVES)
Using a 5 mm hexagon wrench, install the oil nozzle with the
bolt. Install the 6 oil nozzles.
Torque: 8.8 N´m (90 kgf´cm, 78 in.´lbf)
5. INSTALL MAIN BEARINGS
HINT:

Main bearings come in widths of 20.0 mm (0.787 in.) and
23.0 mm (0.906 in.). Install the 23.0 mm bearings in the
No.1 cylinder block journal position with the main bearing
cap. Install the 20.0 mm bearings in the other positions.

Upper bearings have an oil groove and oil holes; lower
bearings do not.
(a) Align the bearing claw with the claw groove of the main
bearing cap or cylinder block.
NOTICE:
Install the bearing with the oil hole in the cylinder block.

P02420
90°Painted Mark
90°
P02197
Seal Width
2 - 3 mm
Seal
Packing
P02104
Z16761
Adhesive EM-92
- ENGINE MECHANICAL (2JZ-GTE)CYLINDER BLOCK
1197 Author
: Date
:
1997 SUPRA (RM502U)
(d) Retighten the connecting rod cap bolts 90° in the numeri-
cal order shown.
(e) Check that the painted mark is now at a 90° angle to the
front.
(f) Check that the crankshaft turns smoothly.
14. CHECK CONNECTING ROD THRUST CLEARANCE
(See page EM-79)
15. INSTALL REAR OIL SEAL RETAINER
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the retainer
and cylinder block.

Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces and sealing groove.

Thoroughly clean all components to remove all de-
bris.

Using a non-residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the retainer as shown in the illustra-
tion.
Seal packing:
Part No. 08826-00080 or equivalent

Install a nozzle that has been cut to a 2 - 3 mm (0.08
- 0.12 in.) opening.

Parts must be assembled within 3 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.

Immediately remove nozzle from the tube and rein-
stall cap.
(c) Install the retainer with the 6 bolts.
Torque: 6.0 N´m (60 kgf´cm, 53 in.´lbf)
16. INSTALL OIL PUMP (See page LU-16)
17. INSTALL WATER PUMP (See page CO-1 1)
18. INSTALL CRANKSHAFT POSITION SENSOR
Torque: 9.0 N´m (90 kgf´cm, 80 in.´lbf)
19. INSTALL RH ENGINE MOUNTING BRACKET AND
INSULATOR ASSEMBLY
Torque: 59 N´m (590 kgf´cm, 44 ft´lbf)
20. INSTALL ENGINE COOLANT DRAIN PLUG
Torque: 30 N´m (300 kgf´cm, 22 ft´lbf)
21. INSTALL UNION FOR OIL COOLER HOSE
(a) Apply adhesive to 2 or 3 threads of the union.
Adhesive:
Part No. 08833-00070, THREE BOND 1324,
or equivalent
(b) Install the union.
Torque: 40 N´m (400 kgf´cm, 30 ft´lbf)

LU050-02
Z02385
A
Seal WidthB
AB
2 - 3 mm
P03946
New
O-Ring
P03936
Long
Bolt LU-16
- LUBRICATIONOIL PUMP
1463 Author
: Date
:
1997 SUPRA (RM502U)
INSTALLATION
1. INSTALL OIL PUMP
(a) Remove any old packing (FIPG) material and be
careful not to drop any oil on the contact surfaces of the
oil pump and cylinder block.

Using a razor blade gasket scraper, remove all the
old packing (FIPG) material from the gasket
surfaces and sealing groove.

Thoroughly clean all components to remove all the
debris.

Using a non-residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the oil pump as shown in the illustra-
tion.
Seal packing:
Part No. 08826-00080 or equivalent

Install a nozzle that has been cut to a 2 - 3 mm (0.08
- 0.12 in.) opening.
HINT:
Avoid applying an excessive amount to the surface. Be particu-
larly careful near oil passages.

Parts must be assembled within 5 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.

Immediately remove nozzle from the tube and rein-
stall cap.
(c) Place 2 new O-rings in position on the cylinder block.
(d) Install the oil pump with the 9 bolts.
Torque: 21 N´m (210 kgf´cm, 15 ft´lbf)
2. INSTALL NO.1 OIL PAN
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the No.1 oil
pan and cylinder block.

Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces and sealing groove.

Thoroughly clean all components to remove all the
debris.

Using a non-residue solvent, clean both sealing
surfaces.
NOTICE:
Do not use a solvent which will affect the painted surfaces.