Page 1321 of 1807

Z09735
B B
A
- ENGINE MECHANICAL (2JZ-GTE)ENGINE UNIT
EM-69
1174 Author: Date:
1997 SUPRA (RM502U)
24. INSTALL PS PUMP
(a) Install the pump bracket with the 3 bolts.
Torque:
A 58 N´m (590 kgf´cm, 43 ft´lbf)
B 39 N´m (400 kgf´cm, 29 ft´lbf)
(b) Install the vane pump with the 2 bolts.
Torque: 58 N´m (590 kgf´cm, 43 ft´lbf)
(c) Connect these hoses:
PS air hose to throttle body
PS air hose to air intake chamber
25. CONNECT FUEL HOSES
(a) Connect the fuel return hose to the fuel return pipe.
(b) Install the fuel return hose to the clamp of the dipstick
guide.
(c) Install the fuel inlet hose with 2 new gaskets and the union
bolt.
Torque: 29 N´m (300 kgf´cm, 22 ft´lbf)
26. CONNECT WIRES AND CONNECTORS
27. CONNECT EVAP HOSE
28. CONNECT BRAKE BOOSTER VACUUM HOSE
29. CONNECT HEATER WATER HOSES
30. INSTALL CHARCOAL CANISTER
31. INSTALL WATER PUMP PULLEY, FAN, FLUID
COUPLING ASSEMBLY AND DRIVE BELT
(See page CO-1 1)
32. M/T:
INSTALL DRIVE BELT TENSIONER DAMPER
(See page EM-21)
33. INSTALL AIR CLEANER AND MAF METER
ASSEMBLY
34. INSTALL NO.1 AIR HOSE
35. CONNECT CONTROL CABLES TO THROTTLE
BODY
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
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 1324 of 1807

P02436
P04469
P04599
Plastigage
P02426
EM-72
- ENGINE MECHANICAL (2JZ-GTE)CYLINDER BLOCK
1177 Author: Date:
1997 SUPRA (RM502U)
Connecting rod thickness:
25.898 - 25.950 mm (1.0196 - 1.0217 in.)
22. REMOVE CONNECTING ROD CAPS AND CHECK
OIL CLEARANCE
(a) Check the matchmarks on the connecting rod and cap to
ensure correct reassembly.
(b) Remove the connecting rod cap bolts.
(c) Using the 2 removed connecting rod bolts, remove the
connecting rod cap and lower bearing by wiggling the
connecting rod cap right and left.
HINT:
Keep the lower bearing inserted with the connecting rod cap.
(d) Clean the crank pin and bearings.
(e) Check the crank pin and bearing for pitting and scratches.
If the crank pin or bearing is damaged, replace the bearings. If
necessary, replace the crankshaft.
(f) Lay a strip of Plastigage across the crank pin.
(g) Install the connecting rod cap with the 2 bolts.
(See page EM-88)
1st 29 N´m (300 kgf´cm, 22 ft´lbf)
2nd Turn extra 90°
NOTICE:
Do not turn the crankshaft.
(h) Remove the 2 bolts, connecting rod cap and lower bear-
ing. (See procedure step (b) and (c))
Page 1325 of 1807

P04470
Z02391
1, 2, 3, 4 or 5Mark
1, 2, or 3 Mark
0, 1 or 2 Mark
No. 1
No. 2
No. 3No. 4No. 6
No. 5
Connecting rod cap
Crankshaft
Use bearingNumber mark
Connecting rod cap º3º +Crankshaft º1º EXAMPLE:
= Total number 4 (Use bearing º4º)0123
12312
01 2
4 2301 2
4 35
- ENGINE MECHANICAL (2JZ-GTE)CYLINDER BLOCK
EM-73
1178 Author: Date:
1997 SUPRA (RM502U)
(i) Measure the Plastigage at its widest point.
Standard oil clearance:
STD 0.023 - 0.041 mm (0.0009 - 0.0016 in.)
U/S 0.25 0.028 - 0.066 mm (0.0011 - 0.0026 in.)
Maximum oil clearance.
STD 0.07 mm (0.0027 in.)
U/S 0.25 0.08 mm (0.0031 in.)
If the oil clearance is greater than maximum, replace the bear-
ings. If necessary, grind or replace the crankshaft.
HINT:
If using a standard bearing, replace with one having the same
number. If the number of the bearing cannot be determined, se-
lect the correct bearing by adding together the numbers im-
printed on the connecting rod cap and crankshaft, then select-
ing the bearing with the same number as the total. There are 5
sizes of standard bearings, marked º1º, º2º, º3º, º4º and º5º ac-
cordingly.
Reference:
Connecting rod big end inside diameter:
Mark º1º55.025 - 55.031 mm (2.1663 - 2.1666 in.)
Mark º2º55.031 - 55.037 mm (2.1666 - 2.1668 in.)
Mark º3º55.037 - 55.043 mm (2.1668 - 2.1670 in.)
Crankshaft crank pin diameter:
Mark º0º51.994 - 52.000 mm (2.0470 - 2.0472 in.)
Mark º1º51.988 - 51.994 mm (2.0468 - 2.0470 in.)
Mark º2º51.982 - 51.988 mm (2.0465 - 2.0468 in.)
Bearing center wall thickness:
Mark º1º1.498 - 1.501 mm (0.0590 - 0.0591 in.)
Mark º2º1.501 - 1.504 mm (0.0591 - 0.0592 in.)
Mark º3º1.504 - 1.507 mm (0.0592 - 0.0593 in.)
Mark º4º1.507 - 1.510 mm (0.0593 - 0.0594 in.)
Mark º5º1.510 - 1.513 mm (0.0594 - 0.0596 in.)
(j) Completely remove the Plastigage.
Page 1326 of 1807

P02288
P04472
Z07401
10
11 12
13 14
5 6
7 8
1 2
3 4
9
P04471
P04792
Plastigage EM-74
- ENGINE MECHANICAL (2JZ-GTE)CYLINDER BLOCK
1179 Author: Date:
1997 SUPRA (RM502U)
23. REMOVE PISTON AND CONNECTING ROD
ASSEMBLIES
(a) Using a ridge reamer, remove all the carbon from the top
of the cylinder.
(b) Push the piston, connecting rod assembly and upper
bearing through the top of the cylinder block.
HINT:
Keep the bearings, connecting rod and cap together.
Arrange the piston and connecting rod assemblies in cor-
rect order.
24. CHECK CRANKSHAFT THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while prying
the crankshaft back and forth with a screwdriver.
Standard thrust clearance:
0.020 - 0.220 mm (0.0008 - 0.0087 in.)
Maximum thrust clearance:
0.30 mm (0.0118 in.)
If the thrust clearance is greater than maximum, replace the
thrust washers as a set.
Thrust washer thickness:
1.940 - 1.990 mm (0.0764 - 0.0783 in.)
25. REMOVE MAIN BEARING CAPS AND CHECK OIL
CLEARANCE
(a) Uniformly loosen and remove the 14 main bearing cap
bolts, in several passes, in the sequence shown.
(b) Using the removed main bearing cap bolts, pry the main
bearing cap back and forth, and remove the main bearing
caps, lower bearings and lower thrust washers (No.4
main bearing cap only).
HINT:
Keep the lower bearing and main bearing cap together.
Arrange the main bearing caps and lower thrust washers
in correct order.
(c) Lift out the crankshaft.
HINT:
Keep the upper bearing and upper thrust washers together with
the cylinder block.
(d) Clean each main journal and bearing.
(e) Check each main journal and bearing for pitting and
scratches.
If the journal or bearing is damaged, replace the bearings. If
necessary, grind or replace the crankshaft.
(f) Place the crankshaft on the cylinder block.
(g) Lay a strip of Plastigage across each journal.
Page 1327 of 1807
P02284
10 11
1213
14 5
6 7
81
2 3
49
P04468
- ENGINE MECHANICAL (2JZ-GTE)CYLINDER BLOCK
EM-75
1180 Author: Date:
1997 SUPRA (RM502U)
(h) Install the main bearing caps.(See page EM-88)
Torque:
1st
44 N´m (450 kgf´cm, 33 ft´lbf)
2nd
Turn extra 90°
NOTICE:
Do not turn the crankshaft.
(i) Remove the main bearing caps.
(See procedure step (a) and (b))
(j) Measure the Plastigage at its widest point.
Standard clearance:
STD
0.026 - 0.040 mm (0.0010 - 0.0016 in.)
U/S 0.25
0.025 - 0.061 mm (0.0010 - 0.0024 in.)
Maximum clearance:
STD
0.06 mm (0.0024 in.)
U/S
0.25: 0.08 mm (0.0031 in.)
Page 1328 of 1807

Z02701
1, 2, 3, 4 or 5Mark 0, 1, 2, 3, 4 Mark
No. 1
No. 2
No. 3
No. 4No. 6
No. 5No. 7
No. 1
No. 2
No. 3
No. 4No. 6
No. 5No. 7 5, 6 or 7
0, 1, 2, 3, 4 Mark
5, 6 or 7 (A)
(B)Cylinder block (A)
Cankshaft (B) =+
Use bearingTotal number º º:Number mark
0 - 2
3 - 56 - 8 9 - 11 12 - 14Cylinder block º3º (A) + Crankshaft º4º(B)
= Total number 7 (Use bearing º3º) EXAMPLE:º1º º2º º3º º4º º5º
Cylinder block number mark Crankshaft
number mark
0123
456
7
11 12223 3
11 22233 3
12 22333 4
222333 44
53334455
33 34455 5
33 44555 5
0
1
2
3
4
2
22 33 3 44 4
6
7
Cylinder block º3º Crankshaft º4º
= Use bearing º3º EXAMPLE: EM-76
- ENGINE MECHANICAL (2JZ-GTE)CYLINDER BLOCK
1181 Author: Date:
1997 SUPRA (RM502U)
If the oil clearance is greater than maximum, replace the bear-
ings. If necessary, grind or replace the crankshaft.
HINT:
If using a standard bearing, replace with one having the same
number. If the number of the bearing cannot be determined, se-
lect the correct bearing by adding together the numbers im-
printed on the cylinder block and crankshaft, then refer to the
table below for the appropriate bearing number. There are 5
sizes of standard bearings, marked º1º, º2º, º3º, º4º and º5º ac-
cordingly.
Standard sized bearing selection chart