Toyota Supra JZA80

Engine unit installation

  1. A/T:
    Check torque converter clutch installation
    Using calipers and straight edge, measure from the installed surface of the torque converter clutch to the front surface of the transmission.
    Correct distance: Less than 0.1 mm (0.004 in.)
    If the distance is not as specified, check for an improper installation.
  2. M/T:
    Install clutch disc and cover
    1. Insert SST in the clutch disc, an then set them and the cover in position.
      SST 09301-001 10
    2. Align the matchmarks on the clutch cover and flywheel.
    3. Tighten the bolts evenly and gradually while pushing SST. Make several passes around the cover until it is snug.
      SST 09301-001 10
    4. Torque the bolts on the clutch cover in the order shown.
      Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
  3. Assemble engine and transmission
    1. M/T:
      Align the input spline with the clutch disc and install the transmission to the engine.
    2. Align the 2 knock pins on the cylinder block with the pin holes of the clutch housing.
    3. Install the transmission with the 6 bolts.
      Torque:
      14 mm head 39 N·m (400 kgf·cm, 29 ft·lbf)
      17 mm head 72 N·m (730 kgf·cm, 43 ft·lbf)
  4. A/T:
    Install torque converter clutch mounting bolts
    1. First, install the gray bolt. Then install 5 black bolts while turning the crankshaft to gain access. Tighten the bolts evenly.
      Torque: 33 N·m (340 kgf·cm, 25 ft·lbf)
    2. Install the hole plug.
  5. A/T:
    Connect throttle cable
  6. A/T:
    Install oil cooler pipe for transmission
    1. Temporarily install the 2 oil cooler pipe, 2 hose clamps and tube clamp with 3 clamp bolts.
    2. Connect the 2 oil cooler tubes to the unions on the transmission. Tighten the union nuts.
      Torque:44 N·m (450 kgf·cm, 33 ft·lbf)
    3. Tighten the 3 clamp bolts.
  7. Install starter
  8. Connect engine wire to transmission
  9. A/T:
    Install oil dipstick and guide for transmission
    1. Install a new O-ring to the dipstick guide.
    2. Connect the dipstick guide end to the dipstick tube of the oil pan.
    3. Install the dipstick guide with the bolt.
    4. Install the dipstick.
  10. Install engine and transmission assembly in vehicle
    1. Attach the engine hoist chain to the engine hangers.
    2. Lower the engine and transmission assembly into the engine compartment.
      Install the engine and transmission assembly carefully without damaging the shift lever retainer (M/T), A/C compressor and PS solenoid valve.
    3. Insert the stud bolts of the front engine mounting insulators into the stud bolt holes of the front suspension crossmember.
    4. Temporarily install the 2 nuts holding the engine front mounting insulators to the front suspension crossmember.
    5. Keep the engine level with a jack.
    6. Remove the hoist chain.
    7. Temporarily install the support member to the engine rear mounting insulator with the 4 nuts.
    8. Install the 4 bolts holding the support member to the body.
      Torque: 25 N·m (260 kgf·cm, 19 ft·lbf)
    9. Tighten the 4 nuts holding the support member to the engine rear mounting insulator.
      Torque: 13 N·m (135 kgf·cm, 10 ft·lbf)
    10. Tighten the 2 nuts holding the engine front mounting insulators to the front suspension crossmember.
      Torque: 59 N·m (600 kgf·cm, 43 ft·lbf)
  11. M/T:
    Install transmission shift lever
    Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
  12. Install propeller shaft (See page PR-11)
  13. A/T:
    Connect transmission control rod
    1. Shift the shift lever to N position.
    2. Fully turn the control shaft lever back and return 2 notches. It is now in neutral position.
    3. Connect the control rod to the shift lever with the nut.
      Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
  14. Install rear center floor crossmember brace
    Torque: 28 N·m (290 kgf·cm, 21 ft·lbf)
  15. Install exhaust pipe heat insulator
  16. Install No.2 front exhaust pipe
    Install a new gasket and the front exhaust pipe with 3 new nuts.
    Torque: 62 N·m (630 kgf·cm, 46 ft·lbf)
  17. Install exhaust pipe assembly
    1. Install the pipe support bracket with the 2 bolts.
      Torque: 43 N·m (440 kgf·cm, 32 ft·lbf)
    2. Install a new gasket and the No.2 front exhaust pipe to the front exhaust pipe with the 2 bolts and 2 new nuts.
      Torque: 58 N·m (590 kgf·cm, 43 ft·lbf)
  18. M/T:
    Install clutch release cylinder and ground strap
    1. Install the clutch release cylinder with the 2 bolts.
      Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
    2. Connect the clutch line tube with the bolt.
      Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
    3. Install the ground strap with the bolt.
      Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
  19. Connect engine wire to cabin
    1. Push in the engine wire through the cowl panel.
      Be careful not to damage the engine wire.
    2. Connect the 2 connectors to the connector cassette.
    3. Connect the connector to the instrument panel wire connector.
    4. Connect the 2 connectors to the ECM.
    5. Connect the connector to the TRAC ECU.
    6. Insert the ECM bracket into the stay on the floor panel.
    7. Install the ECM with the nut.
    8. Install the ECM protector with the 2 nuts.
    9. Install the floor carpet.
    10. Install the scuff plate.
  20. M/T:
    Install upper console panel, shift lever boots and holding bolts
  21. Connect engine wire to cowl panel
  22. Install A/C compressor
    1. Using a torx socket (E10), install the stud bolt and compressor.
      Torque: 26 N·m (265 kgf·cm, 19 ft·lbf)
    2. Connect the compressor connector.
    3. Temporarily install the compressor with nut and 3 bolts.
    4. Alternately tighten the bolt and nut.
      Torque: 52 N·m (530 kgf·cm, 38 ft·lbf)
  23. Install PS pressure feed hose
    Install the pressure feed hose with the 2 clamp bolts.
  24. Install PS pump
    1. Install the pump bracket with the 3 bolts.
      Torque:
      1. 58 N·m (590 kgf·cm, 43 ft·lbf)
      2. 39 N·m (400 kgf·cm, 29 ft·lbf)
    2. Install the pump rear stay with the 2 bolts.
      Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
    3. Install the vane pump to the pump bracket.
    4. Connect these hoses:
      • PS air hose to No.4 timing belt cover.
      • PS air hose to air intake chamber
    5. Install the pump front bracket (See page EM-19).
  25. Install engine wire bracket
  26. Connect fuel hoses
    1. Connect the fuel return hose to the fuel return pipe.
    2. Install the fuel return hose to the clamp of the dipstick guide.
    3. Install the fuel inlet hose with 2 new gaskets and the union bolt.
      Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
  27. Connect wires and connectors
  28. Connect evap hose
  29. Connect brake booster vacuum hose
  30. Connect heater water hoses
  31. Install charcoal canister
  32. Install water pump pulley, fan, fluid coupling assembly and drive belt (See page CO-11)
  33. Install air cleaner, MAF meter, and intake air connector pipe assembly
  34. Connect control cables to throttle body
  35. Fill with fuel
  36. Fill with engine oil
  37. Install radiator assembly (See page CO-28 )
  38. Start engine and check for leaks
  39. Install hood
  40. Road test
    Check for abnormal noise, shock slippage, correct shift points and smooth operation.
  41. Recheck engine coolant and engine oil levels
This guide is based on the book edition Toyota (RM502U, 1997)
Volksbibliothek, info@volksbibliothek.com

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