WPCI ,aa METALHGv5.txtTEXTWPC2 WP_TV22736083WPTVWPC2WPTVWPC2(- 9NetscapeFadrpMOSSM|a,'t  HH  2$HH  Geneva  <Px443!#4$*$$*$ KK  Geneva  Geneva .,6  Geneva   werPC Geneva  werPC Geneva Corel WordPerfect8{WP}014Q3.5.1'3.5.1, 1996 Corel Corporation Limited,Q3.5.1Created with WordPerfect 3.5.1._)#(-_xHH ,6G{HH(d'`aaStylBPSetNPJobZversfSTR ~TStlWDatPtPt  K | sL{WP}01{WP}10' '(-{WP}10 <<KK ..,,..,,  S.O.N.I.C0' '0Preventative Maintenance Tech Notes 1982 to 1985 Supra MA60 series v3.0 0Information provided is given free of charge in good faith without0@prejudice@PP`Table of Contents`ppSection 1 5MGE Engine   1.0 Idling problems Page# 1   1.1 Engine Mechanical General Page# 2   1.2 Cam Belt Replacement Page# 2   1.3 Cooling System Page# 3   1.4 Valvetrain and Cold Startup Page# 3,4 1.5 Exhaust System Page# 4 1.6 Charging System Page# 4Section 2 Drive Train  2.0 Transmission Page# 5 0 2.1 Drive Shafts Page# 50@ 2.2 Differential Carriers Page# 6@P 2.3 Rear axle Short Shafts & Hubs Page# 6P``pSection 3 Suspensionp 3.0 Front StrutsPage# 7 3.1 Rear Suspension Page# 8Section 4 Brakes 4.0 Front Struts Page# 9 ܖSection 1 ~5MGE Engine  !!1.0: Idling problems"" ## 0On a warm day, when restarting the engine, as when leaving a gasstation$%0Por coffee shop after a short visit, the 5MGE engine may exhibit weak%&P`idling, hard starting and putting around at 500 rpm for a short period. If&'`pthis happens only very occasionally it is perfectly normal and is causedby')pa condition called HEAT SOAK which happens after shutting off theengine.J(+ ++ HJܿ,After shutdown the water pump and fan are no longer cooling the engine' 'so.the heat from inside the engine comes out into to engine bay cooking/everything in its way, EFI sensors say "Wahoo sure is hot in here,"gasoline1 in the fuel rail on the intake manifold is boiled {not to mention a hostof3 @other thermodynamic conditions that occur after shutdown}. All4@PEngineering levels are taxed.5P`6`pTo combat this inherit EFI {Electronic Fuel Injection} problem a number 7pfactory installed electronic and mechanical engine control systems are 8used, but under certain conditions they fail to correct the problem 9completely. For the most part EFI is a wonderful system allowing great :fuel economy and silky smooth drive ability so a small bug like HEATSOAK <is still a more livable end than going back to carbs. If this rough idling=symptom is happening more often than seems normal there may be a>problem with one or more of the following: Cold start injector time?switch, Bad Fuel, Throttle position sensor, Plugged or restricted fuel@filter or gas cap, Head Gasket, Air intake leaks, Engine mechanical, EFIA glycol thermo sensor, EFI air temp sensor.B 0C0@1.1: Engine Mechanical GeneralD@PEP`The 5MGE has been bulletproof reliable with many original 1982 1985F`pengines still out there running around the country. SONIC has severalGpmembers including myself that have owned 5MGE's that simply seem toHgo forever and ever, some with over 500,000.00. km's with nothingmoreJthan belts and proper maintenance. One area that can cause someproblemsLwith the 5MGE is related to owner neglect. The coolant system whennotNproperly serviced can lead to engine overheating and cylinder headfailure,PIn extreme cases I have seen 13 year old factory coolant in someSupras.R0Read section 1.3 for more info.S0@ T@P1.2: Cam Belt Replacement!UP`J"V`p `+Vp HJAnother area where problems may occur is related to incorrectlyreplacedXtiming belts. It is imperative that the front crank pulley bolt beproperlyZtorqued with an air impact wrench. Many club members have done back[yard cam belt installs and later found that their front crank harmonic\dampener pulley had come loose damaging the crankshaft keyway,]harmonic dampener and cam belt drive cog. In this dilemma the onlyway_to fix the damage properly is to have the crankshaft and other damaged` parts replaced. The band aid repair is simply to weld the keyway intotheb @crankshaft, and replace other damaged parts ug! c@P dP`When replacing the cam belt for the second time I recommend that you e`preplace the belt tensioner pulley, they have a life expectancy of about fp190,000 km's and will commonly fail if not replaced before thisdistance. hWhen replacing timing belt be sure to use some locktite crank pulleynut.jAlso, use an impact wrench with proper torque setting. If you havekrecently had your cam belt replaced, you should have a reputable shoplcheck your lower crank pulley for tightness. The cam belt should bemadjusted every year or 20,000 km's. This is a very simple procedure:nremove five 10mm bolts holding the 5MGE's front plastic cam beltcover,p then loosen the 14mm bolt on the belt tensioner pulley the pulley willq 0then be pulled by the tensioner spring automatically to the correct beltr0@tension, then tighten the 14mm bolt on the tensioner pulley. You shoulds@Palso check your cam timing after you adjust your belt. Put thecrankshaftuPpat TDC on compression and look to see if the index marks on the camvppulleys are lined up with the index marks on timing cover back plate.wInstall the plastic front timing cover and you are away.x1.3: Cooling SystemyzIt is important to change and flush engine coolant every year; alwaysuse|the best quality product you can buy. The thermostat should also be}changed if there is any instability in the temperature gauge, the gauge~should always run at the same position while cruising down the road. There should be no fluctuations in the gauge reading, such as a steady! climb and fall of the needle over a two minute period. If you notice anyJ" 0  +0 HJmovement you have a problem somewhere in the cooling system IE:clutch@`fan, dirty rad. I recommend using genuine Toyota thermostats as manyof`the after market brands do not work correctly for some unknownreason. Ihave seen some brand new thermostats that can cause the tempfluctuations right out of the Toyota box. Toyota radiator hoses seem tolast forever but be sure to inspect them for cuts and cracks. Fan belts,water pump and the clutch fan should be inspected.I am experimenting with a new product called Polypropylene Glycol  coolant which is non corrosive and safe to the engine and theenvironment.  This coolant offers better heat transfer capabilities than traditional  0Glycol. Another advantage is that it can be run at zero pressure in the  0 @engine with minor modifications to coolant system. Call for more info.  @ P P `Your fan is used to cool your Supra on the highway as well as in slow ` ptraffic around town. Depending on engine load the fan will engage atsome p times to cool the engine and radiator. In the front of the clutch fanthere is a coil loaded thermostatic bimetal coil that will engage the fanbased on air temperature passing by the fan blade. On many older supras after many miles the seals around the temp coil will start to seep theviscous oil from the fan clutch assay, after the loss of the oil over time theclutch fan goes on holidays and your motor gets the added benefit of about 4 0hpand no fresh air intake. One of the symptoms of this problem is a 0 @floating temperature gage. See PMTN for MA60. @ P P `Depending on your body code there are one or more electric fans already ` pinstalled on your supra. If you want, you can wire up a simple relaylogic p box and switch that will allow you to fire the fans at will when the ignition key is in the on position, When you do this make sure you do not confuse any other factory systems, will the fans come on whenever needed. This is a cool upgrade for turbo cars I have my AC fan setup to run for 3  minutes after engine shut down if desired, the MA60's small AC fanJ!  + HJpushes away a wonderous amount of heat from the engine compartment.   Another super upgrade for MA60 is to replace the 5MGE clutch and fan 0with the 7MGTE unit. Some trimming of the fan shroud is needed butyour 0 Psupra will run as cool as a cucumber. The 7M GTE fan and clutch move a P `sizeable amount of extra air through the radiator. ` p p 1.4: Valvetrain and Cold Startup   With most 5MGE engines it is normal to see some chalking of the edgesof  the cam lobes. If you are changing your valve cover gaskets and noticethis  roughness on your cams lobes do not panic. I can recall the first time I  noticed this on my 5MGE when it had only 50,000 km's on it. I went  running to my dealership saying that my engine was defective. At that time my dealership told me not to worry about it and that they would  replace the cams if they became a problem. Several years later after 0looking at the cams in other Supras belonging to other club memberswho 0 Phad their cams replaced by Toyota due to the marks, I realized thatToyota P pwas not telling stories, the new cams looked exactly like mine and my5M p GE now had 95,000kms on it. That was many years ago, today myoriginal 5MGE engine has 322,000.00 kms with out being touched, the camsstill look the same way. I decided to replace my original 5MGE in May 1993 with a super hot HKS tweaked 7MGTE from a crunched 1989 MA71Supra Turbo. Call for more info on the Supra GTE conversion kit.   When you are starting your 5MGE for the first time of the day, many5Ms @will make a loud clackclacking valve lash adjuster noise. The work @ Paround for this problem is simple, shut the engine off immediatelyafter P pstarting, then restart the engine, it will usually run quietly after youdo p this, if not repeat the stop and start. With practice you will find youcanJ  + HJactually just turn the engine over without starting it to achieve thesame result. The 5MGE engine does this because of an air lock condition that occurs in the oil pressure regulator bolted to your cylinder headbetween the cam boxes. This work around makes your starter work harder butthe0result of less wear and tear on your valve train is worth it.0@@PI have seen proof that oil leaks at the exhaust cam box are caused byheatPpgenerated by the exhaust manifold. On a number of cars that had camboxpoil leaks, the leaks went away completely with the installation of an exhaust header.  Turbo magazine and other club members have witnessed the documented durability of my 5MGE. After the many km's it is still a strong engine,it ran most of its whole life with the TRD exhaust header and HKS exhaustsystem. I am sorry to say it is now resting on a wood pallet in my shop,waiting for the day it will again propel a MA60 down the highway.  01.5: Exhaust System0@@PThe only maintenance area relating to the exhaust system is with theP`exhaust manifold on all 5MGE engines. You should also have a closelook`around the motor for cracked, loose or damaged air intake plumbing andvacuum lines. Also retorque all of the 14mm nuts on the manifold toheadand also exhaust header pipe to exhaust manifold. An exhaust header andgood exhaust system are the best upgrades for the MA60. The exhaustsystem will improve fuel economy and performance. The engine will runcooler and have a beautiful exhaust note similar to the purr of a Jaguar,orLotus. HKS make a great 60mm system for the MA60, I think it is soonto be discontinued so act fast there are only a few left in the world. MyHKS @exhaust lasted for over ten years, it is now on a club members car along@Pwith the super high quality TRD exhaust header.P`J `p `+p HJ1.6: Charging SystemMany service shops are replacing the original Denso Toyota Supraalternators with converted GM Delco units. Do not let this happen toyourSupra. The original Denso Toyota alternator is a much better qualityalternator than the GM unit the shop is trying to sell you. Furthermorethe GM unit will not charge the battery when the engine is idling, and canself  destruct if you run your 5MGE to its 6,500 RPM red line frequently.  0 0@Your original alternator is very easy to rebuild and will usually onlyneed @`new brushes. If your Supras emergency brake light and charge warning `plight came on together when your alternator failed, your alternator will pneed a voltage regulator as well as new brushes. The slip rings on the Denso rotor are seldom worn because they are made of stainless steel.With the MA60 series cars there is a common condition with thechargingsystem. It is actually a handy indicator of the problem. If your MA60supra alerts you with a charge warning light and brake warning light atthe same time the problem is in your voltage regulator, located insidethealternator.  0Section 2 ~Drive Train0@2.0: Transmission@P P`For more than a decade the only transmission complaints reported by!`powners are related to how can my Toyota Supra transmission shiftfaster#pand slicker than it does already. Supras have always had very smooth,$strong & slick gearboxes, the 1982 to 1992 {W58} in the MA67 and MA  70&non turbo as well as the super beefy {R154} from the MA71 turbo carhave(all proven bulletproof to the end! Therefore the only suggestion I cangive*you is toward advice on lubrication. Winter cold climates use Dextron11, if bearing noise or hard shifting is experienced when cold, do not beJ - 0  +-0 HJalarmed by a small amount of input shaft bearing noise, this is normal.@Pwith some Toyota transmissions. Also a ticking or slight squeakingsound0Ppcan normally come from the clutch release bearing. Summertime useRed2pLine or Amsoil synthetic gear oil. These oils work wonders in Toyota3boxes, reducing friction and making the gears shift very easily. I run a4W58 transmission in my 82 Supra with a 7MGTE and have experienced5fantastic reliability at over 425 HP. 67The automatic Transmission used in the MA60 series Supras has also 8proven to be bulletproof. Be sure to change the oil regularly. Dirt and oil 9break down are your transmissions only enemy. You change the oil by :draining the transmission pan, please note: you can only change 2 litersof <0the oil at a time; most of the oil is retained in the transmission and =0@converter and will not drain out. Change the oil regularly when you have>@Pyour engine oil changed, this way you will eventually replenish all theold@Ppoil with new.ApB2.1: Drive ShaftsCDSupra drive train components have always been very robust, howeversomeFservice shops always seem to be able to find a way to damage the oddone.HRelating to Drive Shafts be very careful when you are told by a serviceI shop that you need to have your Supras U Joints replaced. In 12 yearswithK this club I have never seen a drive shaft that was so worn out that theL 0joints were loose. If you have a vibration or a noise please do notassumeN0Pthat your drive shaft is worn out. If you let just anybody try to install UOP`Joints in any Supra 1982 to 1992 drive shaft you will most definitelygetQ`your car back with the original noise you were concerned with fixingplusSa few new ones to boot. TUNote: Supra drive shafts almost never fail on their own theyVneed help from: car accidents, rust, inexperienced service shops. WJ!X +X HJ2.2: Differential CarriersYZ The only real problems with the differential in the MA60 series is[ 0relating to the fact the LSD {limited slip differential }clutch pack does\0@not have a great deal of tenson. This means that the differential isloose^@`and does not have much limited slip action. Toyota went to greatlengths``to improve the LSD in the MA70 series and in hindsight made them tooatight. Sure is hard to satisfy everybody.b cAnother condition that may trouble your Supras differential is lack of dregular oil changes, this will lead to differential failure or premature ewear out. The MA60 differential holds a very small amount of oil {1.2 fliters} so it needs to be changed regularly. Cold climates are very hardon hthe differential. I recommend using a good quality synthetic in coldiclimates. I do not recommend standard 80/90 wt oils in any Toyotaj differentials. Using a 75/90 wt LSD differential carrier oil from Fordk 0motor company makes Supra differentials run quieter and smootherthanm0Pany other oils tested. This oil has increased protection for the clutchpackoPpand has proven to be the best differential oil for all Supras from 1982toqp1992. Don't ask me why, all I can say is this oil works like magic.rsNote: A number of club members are using synthetic oils from AmsoilanduEsso in their differentials with good results, one word of cautionshouldwbe noted."synthetic oils may make a some differentials that are alreadyxnoisy, noisier."yz 2.3: Rear Axle Short Shafts & Hubs{ 0|0@Unlike the front wheels hub and spindle setup the rear wheels are spunon~@`a two piece splined short shaft assembly that is installed into the rear`pcontrol arms on tapered bearings with a crush sleeve preload setup, thepsame way a pinion shaft is installed into a differential. Because of this crush sleeve arrangement it is impossible to just quickly disassembletheJ! +  HJshort shafts for service and greasing. Because of the unserviceabilityofthis area, it never gets serviced, and as it turns out it the short shaftshave never been any problems what so ever. The only way you can hurtthem is with curbs and accidents. I am telling you all about thisbecause I used to spend some time wondering how long this setup will last. My 0conclusion is: my Supra now has 325 HP and 330,000 km's on thefactory0Pshafts and still no problems other than some tolerance in the shortshaftPpspines. "If it aint broke don't fix it."p Section 3 ~Suspension  3.0: Front Struts  Many years ago when the 1982 and 1983 MA60's were almost newdealerships around the country were receiving complaints from Supraowners relating to wheel vibrations and shimmies felt in the steeringwheel. Depending on which dealer you were talking to the story was different, 0some were saying the suspension had a design flaw while others were0@blaming the Dunlop D series tires. After my dealer had completed their@Pfifth try at rebalancing my Supras wheels, I decided that the problemP`was not related to the wheels or tires.`ppBy taking a fresh approach to solving the problem I discovered a coupleofthings that could be causing the vibes. The first area was relating tothefront suspensions tension compression rods bushings, the bushingswerevery soft and allowed the front wheels considerably soft pinning. Byfabricating some steel inserts I was able to tighten the bushingsconsiderably. This was a worth while upgrade, my car handled superblyand had considerably reduced steering wheel vibes. when disassembling the 0tension compression rods I was amazed at how worn my factory stock 0@front struts looked; some leaking as well as worn shock shafts. Idecided!@`to replace the stock oil based front struts with an aftermarket KYB6 `+  H6GR2`gas front strut. Prestosolveo! my Supras wheel vibes were nowhere tobefound.I passed this information on to a number of the local Toyota dealershipsas well as to Toyota Canada. Shortly later in the second quarter 1984Supras were shipping with upgraded tension compression rod bushingskitpart #4867419105 as well as upgraded gas charged front struts.   0Years later I learned through the grape vine that the original test mules 0@that went to lotus had much stiffer T.C. rod bushings but they did notmake @`production. The moral of this story is; if your Supra has front wheelvibes `felt through your steering wheel if may not be your wheel balance. 3.1: Rear SuspensionThe rear suspension on the MA60 has proven to be very robust andsimpleto set up. The only adjustments are for toe in. camber is not adjustableand this leads me into an area that needs to be mentioned. If your rearsuspension feels low or you notice wheel hop when you spin the tires onslippery road surfaces you should upgrade your rear shocks. Clubmembers0have tested may types of rear shocks and the best ones are of the Gas0@types made by KYB or Tokico. This is the only upgrade that you should doto@`your rear suspension. I have tried and have also seen a number of club`pmembers using aftermarket springs of all different types {TRD, EIBACH,pSUSPENSION TECHNIQUES} etc in the MA60 series Supras, this is thebestway I know of to screw up a MA60's handling and performance. Beentheredone that. After upgrading my 1982 MA67 to the 1989 7MGTE engine Itried a number of things to try to get the car to hook up in a straightlineand around corners.  See Turbo & High Tech letter text insertJ! 0  + 0 HJ"Some of the changes I made to get the car hooked up were to replaceall@`the shocks and struts, they seemed as if they were in fine shape withthe`160 hp 5MGE, but with the new potent turbo engine the supra was ahandful to say the least. I used locally available KYB's that I have hadgreat success with in the past. I also found that the rear suspensionridehight was critical to optimum performance! It should be as close tofactory spec as possible, I use the stock GTS front & rear springs. Shortsprings cause the rear suspension to have way to much negative camberunder acceleration making the car loose bite and snake of sideways. The stock rear springs and KYB shocks helped reduce the wheel spin as wellas  settled down the tendency to over steer in a straight line. I alsoinstalled  @a new set of tires, BFG Comp T/A's, 2455016's in rear and 22550  16's @`up front replacing the very old first generation Goodyear Gatorback 225 `p5016's at all four corners. This reduced the wheel spin considerably,andpallowed me get on the car harder in first gear than was previouslypossible with the old setup. As well the slightly taller rear tire's nowmake overall gearing factory stock, 2450 RPM at 100 KPH. I can't seemtoget total control of wheel spin in first gear on all road surfaces.Sometimes second gear can cause wheel spin and over steeringproblems if the attitude of the car is anything other than perfectly straight. It comes in right after the Turbo spools. Proverb; Plentyohorspower  "IT IS DIFFICULT TO MAKE ANY 3100 LB VEHICLE WITH 300 + HP NOTSPIN @THE WHEELS." @ P P `Some of you may remember that the MA60 suspension was set up by a ` pEnglish car company called LOTUS. Toyota owned a good sized chunk of p Lotus during the time of MA60 development. Lotus set the overallfactory spring rate to work well on the street under many different road conditions. If you are setting up an MA60 for autocrossing or slalomyou then may want to look into the TRD or Eibach spring setups. TheexcessiveJ  +  HJnegative rear camber that rips the inside off your rear tires on thestreet!! is an advantage going around a racetrack. If your Supra has more than300! !@hp under the hood the stock springs will be your best choice for 1/4mile !@!`times. !`!p !p!Section 4 ~brakes !!4.0: Brakes!!!!Brakes on all years of MA60 series cars are very good. The onlyproblem !!with them is relating to the fact that the pad material is so hard the !!brakes seem to last for ever. It is not uncommon to see MA60s withover !"200,000 kms on the original front and rear pads and rotors. Due to theuse "" of this hard material in the pads some cars will develop rotor fade " "0causing high rotors temperatures, causing the rotors to go out of round. "0"@On two occasions I have removed the front rotors from my Supra tohave"@"`them cut down, I then put them back on the car with out changing thepads."`"""On cars driven in salty conditions it is normal to see the rotorscorroding""very badly causing the cooling fins to become ineffective. Aftermarket ""rotors are cheaper but will wear down if you use the stock pads. If youuse"""aftermarket rotors use aftermarket pads as well. Many years ago asmart$"#guy told me "never handle new brake pads or rotor surfaces with yourbare&## hands because the oil on your skin will cause glazing of the padmaterial. I(# #@have had many people crying with tears over this but to this day I have)#@#Pstill not proven this statement wrong or right. I still use it todaybecause+#P#pit makes a certain amount logical sense, why do I have to touch the,#p#surface to install the parts? I dont.-##.##Currently I am researching high performance aftermarket brakes for myJ/## #+/ # HJSupra. I need to make my car stop better than the stock brakes arecapable1##of. My Supra is a dangerously fast car.2##3#$Another important tip for all MA60 cars is to be sure not to overtighten5$$ the wheel lugs. The factory torque spec is 55 foot/pounds, alwaystorque7$ $@to this value. I have seen Supras where the wheels lugs were torqued to8$@$Pvery high values 140 foot/pounds, this can cause rotor distortion9$P$`resulting in brake peddle pulsation. I always torque the wheel nuts witha;$`$torque wrench. <$$ =$$Always check all your brake lines, it is very rare to find cracked linesbut ?$$on cars driven in cold climates sometimes have fine cracks. Anothergood A$$preventive Maintenance tip is to flush your brake and clutch master B$$cylinders reservoir out with new fluid every two years, always usegoodD$%quality fluid and be careful not to spill any brake fluid on your SuprasE%% paint because it will damage the paint on your car.F% %0G%0%@H%@%PI%P%`End of File! (- \\ (-J%`%pK%p%/L%%{SONIC} Supra Owners Network In CanadaM%%FROM THE HOME OF THE SUPRA GTEN%%Information provided is given free of charge in good faith withoutprejudice.P%%Calgary Alberta Canada. T2V3G6 Hm#4032593106Q%%\R%%