1997 TOYOTA SUPRA lock

Z00570
Radiator Cap Tester
30° or More
Radiator Cap
P11504
CO08U-01
CO-18
- COOLINGRADIATOR
1431 Author
: Date
:
1997 SUPRA (RM502U)
ON-VEHICLE INSPECTION
1. REMOVE RADIATOR CAP
CAUTION:
To avoid the danger of being burned, do not remove the ra-
diator cap while the engine and radiator are still hot, as fluid
and steam can be blown out under pressure.
2. INSPECT RADIATOR CAP
NOTICE:

If the radiator cap has contaminations, always rinse
it with water.

When performing steps (a) and (b) below, keep the ra-
diator pump tester at an angle of over 30° above the
horizontal.
(a) Before using a radiator cap tester, wet the relief valve and
pressure valve with engine coolant or water.
(b) Using a radiator cap tester, slowly pump the tester and
check that air is coming from the vacuum valve.
Pump speed: 1 push/ (3 seconds or more)
NOTICE:
Push the pump at a constant speed.
If air is not coming from the vacuum valve, replace the radiator
cap.
(c) Pump the tester and measure the relief valve opening
pressure.
Pump speed: 1 push within 1 second
NOTICE:
This pump speed is for the first pump only (in order to close
the vacuum valve). After this, the pump speed can be re-
duced.
Standard opening pressure:
93 - 123 kPa (0.95 - 1.25 kgf/cm
2, 13.5 - 17.8 psi)
Minimum opening pressure:
78 kPa (0.8 kgf/cm
2, 11.4 psi)
HINT:
Use the tester's maximum reading as the opening pressure.
If the opening pressure is less than minimum, replace the radia-
tor cap.
3. INSPECT COOLING SYSTEM FOR LEAKS
(a) Fill the radiator with coolant, and attach a radiator cap tes-
ter.
(b) Warm up the engine.
(c) Pump it to 147 kPa (1.5 kgf/cm
2, 21.3 psi), and check that
the pressure does not drop.
If the pressure drops, check the hoses, radiator or water pump
for leaks.
If no external leaks are found, check the heater core, cylinder
block and cylinder head.
4. REINSTALL RADIATOR CAP

P02651Stopper BoltSST
Lock
Plate
CO1205Overhaul Handle Dimension º B º
SSTPart º A º
ClawStopper Bolt
CO08X-01
P11773
Lightly
Ta p
Z16737
Inlet Pipe A/T CO-24
- COOLINGRADIATOR
1437 Author
: Date
:
1997 SUPRA (RM502U)
DISASSEMBLY
1. REMOVE CUSHIONS FROM RADIATOR
2. ASSEMBLE SST
SST 09230-01010
(a) Install the claw to the overhaul handle, inserting it in the
hole in part ºAº as shown in the installation.
(b) While gripping the handle, adjust the stopper bolt so that
dimension ºBº shown in the diagram is 0.2 - 0.5 mm
(0.008 - 0.020 in.).
NOTICE:
If this adjustment is not done, the claw may be damaged.
3. UNCAULK LOCK PLATES
Using SST to release the caulking, squeeze the handle until
stopped by the stopper bolt.
SST 09230-01010
4. REMOVE TANKS AND O-RINGS
(a) Lightly tap the radiator hose inlet (or outlet) with a soft-
faced hammer and remove the tank.
(b) Remove the O-ring.
5. A/T:
REMOVE OIL COOLER FROM LOWER TANK
(a) Remove the inlet pipes.
HINT:
Make a note of the direction to face the pipes.
(b) Remove the nuts, plate washers and oil cooler.
(c) Remove the O-rings from the oil cooler.

CO08Y-02
Z16734
A/T
(1)
(2)(4)
(3)(5)(6)
Z16738
A/T
(6)
CO1267
Lock Plate
Lock Plate
Core
CO0317
O-RingO Normal
X Twisted X Twisted
P10899
CORRECT
Tank
WRONGLock
Plate
- COOLINGRADIATOR
CO-25
1438 Author
: Date
:
1997 SUPRA (RM502U)
REASSEMBLY
1. A/T:
INSTALL OIL COOLER TO LOWER TANK
(a) Clean the O-ring contact surface of the lower tank and oil
cooler.
(b) Install new O-rings (1) to the oil cooler (2).
(c) Install the oil cooler (2) to the lower tank (3).
(d) Install the plate washers (4), and nuts (5).
Torque: 8.3 N´m (85 kgf´cm, 74 in.´lbf)
(e) Install the inlet pipes (6).
Torque: 15 N´m (150 kgf´cm, 11 ft´lbf)
HINT:
Face the inlet pipes in the same direction they were before dis-
assembly.
2. INSPECT LOCK PLATE
Inspect the lock plate for damage.
HINT:

If the sides of the lock plate groove are deformed, reas-
sembly of the tank will be impossible.

Therefore, first correct any deformation with pliers or simi-
lar object. Water leakage will result if the bottom of the
lock plate groove is damaged or dented. Therefore, repair
or replace if necessary.
NOTICE:
The radiator can only be recaulked 2 times.
After the 2nd time, the radiator core must be replaced.
3. INSTALL NEW O-RINGS AND TANKS
(a) After checking that there are no foreign objects in the lock
plate groove, install the new O-ring without twisting it.
HINT:
When cleaning the lock plate groove, lightly rub it with sand pa-
per without scratching it.
(b) Install the tank without damaging the O-ring.
(c) Tap the lock plate with a soft-faced hammer so that there
is no gap between it and the tank.

CO1206Overhaul Handle Dimension º B º
SSTPart º A º
Punch AssemblyStopper Bolt
Z09523
1
SSTTank
Lock
Plate
Stopper Bolt58
64 3
72
P11771
Bracket Tank Rib
Pipe
P11772
CO-26
- COOLINGRADIATOR
1439 Author
: Date
:
1997 SUPRA (RM502U)
4. ASSEMBLE SST
SST 09230-01010, 09231-14010
(a) Install the punch assembly to the overhaul handle, insert-
ing it in the hole in part ºAº as shown in the illustration.
(b) While gripping the handle, adjust the stopper bolt so that
dimension ºBº shown in the diagram.
Dimension ºBº:
8.4 mm (0.34 in)
5. CAULK LOCK PLATE
(a) Lightly press SST against the lock plate in the order
shown in the illustration. After repeating this a few times,
fully caulk the lock plate by squeezing the handle until
stopped by the stopper plate.
SST 09230-01010
HINT:

Do not stake the areas protruding around the pipes,
brackets or tank ribs.

The points shown in the rib sides and oil cooler near here
cannot be staked with SST. Use a plier or similar object
and be careful not to damage the core plates.

P02648
H
P04580
SST
B02745
Clearance
Lock
Plate
O-Ring
- COOLINGRADIATOR
CO-27
1440 Author
: Date
:
1997 SUPRA (RM502U)
(b) Check the lock plate height (H) after completing the caulk-
ing.
Plate height:
7.40 - 7.80 mm (0.2959 - 0.3119 in)
If not within the specified height, adjust the stopper bolt of the
handle again and caulk again.
6. INSPECT FOR WATER LEAKS
(a) Tighten the drain plug.
(b) Plug the inlet and outlet pipes of the radiator with SST.
SST 09230-01010
(c) Using a radiator cap tester, apply pressure to the radiator.
Test pressure:
177 kPa (1.8 kgf/cm
2, 26 psi)
(d) Inspect for water leaks.
HINT:
On radiators with resin tanks, there is a clearance between the
tank and lock plate where a minute amount of air will remain,
giving the appearance of an air leak when the radiator is sub-
merged in water. Therefore, before doing the water leak test,
move the radiator around in the water until all air bubbles disap-
pear.
7. INSTALL CUSHIONS TO RADIATOR

- DIAGNOSTICSENGINE (2JZ-GTE)
DI-159
387 Author
: Date
:
1997 SUPRA (RM502U)DTC No.
(See Page)
Detection ItemTrouble AreaMIL*Memory
P0135
(DI-197)Heated Oxygen Sensor Heater
Circuit Malfunction
(Bank 1 Sensor 1)Open or short in heater circuit of heated oxygen sensor
Heated oxygen sensor heater
ECM

P0136
(DI-199)Heated Oxygen Sensor Circuit
Malfunction
(Bank 1 Sensor 2)
Heated oxygen sensor
P0141
(DI-197)Heated Oxygen Sensor Heater
Circuit Malfunction
(Bank 1 Sensor 2)
Same as DTC No. P0135
P0171
(DI-201)System too Lean
(Fuel Trim)
Air Intake (hose loose)
Fuel line pressure
Injector blockage
Heated oxygen sensor malfunction
Mass air flow meter
Engine coolant temp. sensor

P0172
(DI-201)System too Rich
(Fuel Trim)
Fuel line pressure
Injector blockage, leak
Heated oxygen sensor malfunction
Mass air flow meter
Engine coolant temp. sensor

P0300
(DI-204)Random / Multiple Cylinder
Misfire DetectedIgnition system
In
jector
P0301
P0302
P0303
P0304
P0305
P0306
(DI-204)Misfire Detected
- Cylinder 1
- Cylinder 2
- Cylinder 3
- Cylinder 4
- Cylinder 5
- Cylinder 6
Injector
Fuel line pressure
EGR
Compression pressure
Valve clearance not to specification
Valve timing
Mass air flow meter
Engine coolant temp. sensor

P0325
(DI-209)Knock Sensor 1 Circuit
MalfunctionOpen or short in knock sensor 1 circuit
Knock sensor 1 (looseness)
ECM

P0330
(DI-209)Knock Sensor 2 Circuit
MalfunctionOpen or short in knock sensor 2 circuit
Knock sensor 2 (looseness)
ECM

P0335
(DI-212)Crankshaft Position
Sensor ºAº Circuit
Malfunction
Open or short in crankshaft position sensor circuit for NE sig-
nal
Crankshaft position sensor for NE signal
Starter
ECM

*: ... MIL lights up

DI-160
- DIAGNOSTICSENGINE (2JZ-GTE)
388 Author
: Date
:
1997 SUPRA (RM502U)DTC No.
(See Page)
Detection ItemTrouble AreaMIL*Memory
P0340
(DI-215)Camshaft Position Sensor
Circuit Malfunction
Open or short in camshaft position sensor circuit
Camshaft position sensor
Open or short in crankshaft position sensor circuit for NE2
signal
Crankshaft position sensor for NE2 signal
Starter
ECM

P0401
(DI-217)Exhaust Gas Recirculation Flow
Insufficient Detected
EGR valve stuck closed
Short in VSV circuit for EGR
Open in EGR gas temp. sensor circuit
EGR hose disconnected
ECM

P0402
(DI-227)Exhaust Gas Recirculation Flow
Excessive Detected
EGR valve stuck open
EGR VSV open malfunction
Open in VSV circuit for EGR
Short in EGR gas temp. sensor circuit
ECM

P0420
(DI-231)Catalyst System Efficiency
Below ThresholdThree-way catalytic converter
Open or short in heated oxygen sensor circuit
Heated oxygen sensor

P0441
(DI-234)Evaporative Emission Control
System Incorrect Purge Flow
Open or short in VSV circuit for EVAP
VSV for EVAP
ECM
Vacuum hose blocked or disconnected
Charcoal canister

P0500
(DI-238)Vehicle Speed Sensor
Malfunction
Open or short in vehicle speed sensor circuit
Vehicle speed sensor
Combination meter
ECM

P0505
(DI-240)Idle Control System Malfunction
IAC valve is stuck or closed
Open or short in IAC valve circuit
Open or short in A/C signal circuit
Air intake (hose loose)

P0510
(DI-243)Closed Throttle Position Switch
MalfunctionOpen in closed throttle position switch circuit
Closed throttle position switch
ECM

*: ... MIL lights up

DI4SK-01
S00576
P11278
ECM
FI6451
CHECK HARNESS A
ECU
FI6522
Before Connection
After Connection
Female
Connector Bolt
Collar
Stopper
Nut
Connector
Male
FI6523
Less Than 1 mm (0.04 in.) DI-164
- DIAGNOSTICSENGINE (2JZ-GTE)
392 Author
: Date
:
1997 SUPRA (RM502U)
TERMINALS OF ECM
Connectors of the ECM are water-proof and are the bolt type.
For water proof type connectors, in order to measure the volt-
age of ECM terminals and the resistance of connected parts,
connect the inspection check harness between the ECM and
vehicle wire harness, then perform the inspection.
The inspection method of inserting a tester probe from the other
side of connector noticeably reduces the water-proof ability.
Disconnect the connector by fully loosening the bolt.
PREPARATION
(a) Turn the ignition switch to LOCK position.
(b) Turn up the passenger side floor mat.
(c) Remove the ECM protector.
(d) Disconnect the connectors from the ECM.
After completely loosening the bolt, the 2 parts of connec-
tor can be separated.
NOTICE:

Do not pully the wire harness when disconnecting the
connector.

When disconnecting the connector, the ECM's back-
up power source is cut off, so the DTC, etc. recorded
in the ECM memory are cancelled.

Never insert a tester probe or male terminal used for
inspection purposes into the female terminal of the
vehicle wire harness. Otherwise, the female terminal
may be widened, which can result in faulty connec-
tion.
(e) Connect the Check Harness A between ECM and con-
nector of vehicle wire harness.
SST 09990-01000
HINT:
The arrangement of the DLC1 terminals are the same as those
of the ECM (See page DI-164).
(f) Disconnect the Check Harness A.
(g) Reconnect the connectors to the ECM.
(1) Match the male connector correctly with female
connector, then press them together.
(2) Tighten the bolt.
Make sure the connector is completely connected,
by tightening the bolt until there is a clearance of
less than 1 mm (0.04 in.) between bottom of the
male connector and end of the female connector.
(h) Install the ECM protector and floor mat.