LEXUS GS400 2000 Service Repair Manual

A02728
Dark Green
A09755
Case
Clamp
A02761
New O±Ring
PushClamp
A02799
A02795
± ENGINE MECHANICAL (2JZ±GE)ENGINE UNIT
EM±69
1423 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
(b) Hold the crankshaft pulley bolt with a wrench, and install
the 6 bolts evenly.
Torque: 48 N´m (490 kgf´cm, 35 ft´lbf)
HINT:
First install the dark green colored bolt, install the other bolts.
(c) Install the hole plug.
7. INSTALL OIL COOLER PIPE FOR A/T
8. INSTALL EXHAUST MANIFOLD
(a) Install 2 new gaskets to the cylinder head.
(b) Using a 14 mm deep socket wrench, install the exhaust
manifold with the 8 nuts. Uniformly tighten the nuts in sev-
eral passes.
Torque: 40 N´m (408 kgf´cm, 30 ft´lbf)
(c) Connect the heated oxygen sensor (bank 2 sensor 1)
connector.
(d) Install the case clamp.
9. INSTALL OIL DIPSTICK GUIDE AND DIPSTICK FOR
A/T
(a) Install a new O±ring to the dipstick guide.
(b) Push in the dipstick guide end to the dipstick tube of the
oil pan.
(c) Install the dipstick guide with the bolt.
(d) Connect the engine wire clamp to the dipstick guide.
(e) Install the dipstick.
10. INSTALL ENGINE AND TRANSMISSION ASSEMBLY
IN VEHICLE
(a) Attach the engine chain hoist to the engine hangers.
(b) Slowly lower the engine and transmission assembly into
the engine compartment.
(c) Insert the stud bolts of the front engine mounting brackets
into the stud bolt holes of the front suspension crossmem-
ber.
(d) Keep the engine level.
(e) Install the rear engine mounting member with the 4 bolts
and 4 nuts.
Torque:
25.5 N´m (260 kgf´cm, 19 ft´lbf) for bolts
13.5 N´m (135 kgf´cm 10 ft´lbf) for nuts
NOTICE:
Be careful of installation direction.

A02796
A02752
A02789
A02791
A02792
(2)
(4)(3)
EM±70
± ENGINE MECHANICAL (2JZ±GE)ENGINE UNIT
1424 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
(f) Install the 4 nuts holding the engine mounting brackets to
the front suspension crossmember.
Torque: 70 N´m (714 kgf´cm, 52 ft´lbf)
(g) Install the 2 hole plugs.
(h) Remove the engine chain hoist.
(i) Remove the bolt and No.1 engine hanger.
11. INSTALL PS GEAR HOUSING
(a) Align the matchmarks and connect the sliding yoke to the
steering intermediate shaft.
(b) Install the PS gear housing with the 4 bolts.
Torque: 65 N´m (660 kgf´cm, 48 ft´lbf)
(c) Install the bolt holding the sliding yoke to the steering in-
termediate shaft.
Torque: 35 N´m (360 kgf´cm, 26 ft´lbf)
(d) Connect the PS pressure switch and wire clamp.
12. INSTALL TRANSMISSION CONTROL ROD
Install the control rod with the 2 nuts.
Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)
If the indicator is not aligned with the correct position, carry out
the following adjustment procedures.
(1) Loosen the nut on the shift lever.
(2) Push the control shaft lever fully rearward.
(3) Return the control shaft lever 2 notches to the N
position.
(4) Set the shift lever to the N position.
(5) While holding the shift lever lightly toward the R
position side, tighten the nut.
Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)

A02794
A02804A BA
A02823
A02786
A02759
Ground
Cable
± ENGINE MECHANICAL (2JZ±GE)ENGINE UNIT
EM±71
1425 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
13. INSTALL A/C COMPRESSOR AND PS PUMP
(a) Temporarily install the compressor with the 2 bolts.
(b) Using a torx socket (E10), install the stud bolt.
Torque: 26 N´m (265 kgf´cm, 19 ft´lbf)
(c) Tighten the nut and 2 bolts.
Torque: 52 N´m (530 kgf´cm, 38 ft´lbf)
(d) Connect the compressor connector.
(e) Connect the PPS solenoid valve connector.
(f) Install the vane pump assembly with the 3 bolts and plate
washer.
Torque:
57.9 N´m (590 kgf´cm, 43 ft´lbf) for A bolts
52 N´m (530 kgf´cm, 38 ft´lbf) for B bolt
(g) Install the pump rear stay with the 2 bolts.
Torque: 39.2 N´m (400 kgf´cm, 29 ft´lbf)
(h) Connect the PS air hose to the No.4 timing belt cover.
(i) Connect the PS air hose to the air intake chamber.
14. CONNECT ENGINE WIRE TO ECM BOX
(a) Install the engine wire grommet to the ECM box.
(b) Connect the 3 ECM connectors.
(c) Connect the 4 wire harness connectors.
(d) Connect the 2 junction connectors.
(e) Install the ECM cover and ECM hood.
15. CONNECT CLAMPS, WIRES, CONNECTORS, HOSES,
CABLE AND STRAP
(a) Connect the 2 engine wire clamps to the clamp brackets.
(b) Connect the DLC1.
(c) Connect the igniter connector.
(d) Connect the ground cable to the bracket on the cylinder
block.
(e) Connect the engine wire clamp to the wire clip of the gen-
erator.
(f) Connect the generator wire.

A02765
EVAP Hose
A02751
A02753
EVAP
Hose Clamp
MAF Meter
Connector
EM±72
± ENGINE MECHANICAL (2JZ±GE)ENGINE UNIT
1426 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
(g) Connect the heated oxygen sensor (bank 1 sensor 1)
connector.
(h) Connect the heated oxygen sensor (bank 1 sensor 2)
connector.
(i) Connect the EVAP hose to the pipe (from charcoal canis-
ter).
(j) Connect the heater hose to the heater pipe.
(k) Connect the heater hose to the water bypass pipe.
(l) Connect the ground strap to the dash panel.
(m) Connect the fuel inlet hose to the fuel pipe support.
Torque: 29 N´m (300 kgf´cm, 22 ft´lbf)
(n) Connect the starter wire to the terminal and manifold stay.
(o) Connect the ground wire to the floor.
16. INSTALL FRONT SUSPENSION MEMBER BRACE
Install the brace with the 6 bolts.
Torque: 58 N´m (590 kgf´cm, 43 ft´lbf)
17. INSTALL DRIVE BELT (See page CH±1)
18. INSTALL RADIATOR ASSEMBLY (See page CO±23)
19. CONNECT ACCELERATOR CABLE TO ENGINE
20. INSTALL AIR CLEANER, MAF METER AND INTAKE
AIR CONNECTOR PIPE ASSEMBLY
(a) Connect the intake air resonator to the throttle body.
(b) Install the air cleaner case with the 3 bolts.
(c) Tighten the hose clamp bolt holding the intake air resona-
tor to the throttle body.
(d) Connect the MAF meter connector.
(e) Connect the engine wire clamp to the air cleaner case.
(f) Connect the EVAP hose to the air cleaner case.
(g) Connect the PS air hose to the No.4 timing belt cover.
(h) Connect the PCV hose to the No.2 cylinder head cover.
21. INSTALL AIR CLEANER INLET
22. INSTALL ENGINE COVER
Install the engine cover with the 4 nuts.
23. FILL WITH ENGINE COOLANT
24. FILL WITH ENGINE OIL
25. START ENGINE AND CHECK FOR LEAKS
26. INSTALL ENGINE UNDER COVER

± ENGINE MECHANICAL (2JZ±GE)ENGINE UNIT
EM±73
1427 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
27. INSTALL HOOD
NOTICE:
Be careful not to damage the body or glass with the hood
end.
28. PERFORM ROAD TEST
Check for abnormal noise, shock, slippage, correct shift points
and smooth operation.
29. RECHECK ENGINE COOLANT AND OIL LEVELS

EM0DJ±03
A02768
N´m (kgf´cm, ft´lbf) : Specified torque
 Non±reusable part

Precoated partRH Engine Mounting Bracket and Insulator Assembly
No.2 Water Bypass Pipe with Hose
 Gasket
Water Pump

Engine Coolant Drain Plug
 O±Ring
21 (210, 15)
 O±Ring O±RingKnock Sensor 1
Knock Sensor 2
GeneratorFuel Inlet Pipe
Oil Pump
 Crankshaft Front Oil Seal
Oil Filter and
Bracket AssemblyNo.1 Oil Pipe
Union Bolt
55 (550, 41) Gasket
90 (900, 66)Union Bolt

Oil Pressure Switch
 Gasket21 (210, 15)
x 9
 O±Ring
x 6
x 6x 16
 Gasket
No.1 Oil Pan
Oil Pan Baffle Plate
Oil Strainer
LH Engine Mounting Bracket
and Insulator Assembly
 Gasket
x 16
No.2 Oil Pan
x 6
Drain Plug
EM±74
± ENGINE MECHANICAL (2JZ±GE)CYLINDER BLOCK
1428 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
CYLINDER BLOCK
COMPONENTS

A02806
Piston Ring (No.1 Compression)
Piston Ring
(Side Rail and Expander)Piston Ring (No.2 Compression)
Piston Pin
 Connecting Rod Bushing
Connecting Rod
Connecting Rod Bearing
Rear Oil Seal Retainer Piston
 Snap Ring
 Snap Ring
Connecting Rod Cap
 Crankshaft Rear Oil Seal
x 6
Cylinder Block
Crankshaft
Crankshaft Thrust Washer
Main Bearing CapMain Bearing
N´m (kgf´cm, ft´lbf) : Specified torque
 Non±reusable part
See page EM±91
1st 30 (300, 22)
2nd Turn 90°
See page EM±91
1st 45 (450, 33)
2nd Turn 90°
± ENGINE MECHANICAL (2JZ±GE)CYLINDER BLOCK
EM±75
1429 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)

EM0DK±03
P02447
EM±76
± ENGINE MECHANICAL (2JZ±GE)CYLINDER BLOCK
1430 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
DISASSEMBLY
1. INSTALL ENGINE TO ENGINE STAND FOR
DISASSEMBLY
2. REMOVE GENERATOR
Remove the bolt, nut, pipe bracket and generator.
3. REMOVE TIMING BELT AND PULLEYS
(See page EM±16)
4. REMOVE NO.2 WATER BYPASS PIPE WITH HOSE
Remove the bolt, 2 nuts, No.2 water bypass pipe and gasket.
5. REMOVE WATER PUMP
Remove the 6 bolts, water pump and O±ring.
6. REMOVE CYLINDER HEAD (See page EM±33)
7. REMOVE OIL PRESSURE SWITCH AND KNOCK
SENSORS
Using SST, remove the switch and sensors.
SST 09816±30010
8. REMOVE OIL FILTER AND BRACKET ASSEMBLY
(a) Remove the union bolt and oil filter bracket.
(b) Remove the gasket from the union bolt.
(c) Remove the O±ring from the oil filter bracket.
9. REMOVE NO.1 OIL PIPE
Remove the union bolt, No.1 oil pipe and 2 gaskets.
10. REMOVE FUEL INLET PIPE
Remove the 2 bolts and fuel inlet pipe.
11. REMOVE LH ENGINE MOUNTING BRACKET AND
INSULATOR ASSEMBLY
Remove the 4 bolts and mounting bracket.
12. REMOVE RH ENGINE MOUNTING BRACKET AND
INSULATOR ASSEMBLY
Remove the 4 bolts and mounting bracket.
13. REMOVE OIL PUMP (See page LU±6)
14. REMOVE REAR OIL SEAL RETAINER
(a) Remove the 6 bolts of the retainer.
(b) Remove the oil seal retainer by prying the area between
the oil seal retainer and main bearing cap with a screw-
driver.

P04467
P02436
P04469
P04599
Plastigage
P02426
± ENGINE MECHANICAL (2JZ±GE)CYLINDER BLOCK
EM±77
1431 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
15. 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.
Connecting rod thickness:
25.898 ± 25.950 mm (1.0196 ± 1.0217 in.)
16. 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±91)
Torque:
1st 30 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 (b) and (c) above)

P04470
Z02391
Mark
1, 2, 3 , 4 or 5
Mark
1, 2 or 3
Mark
0, 1 or 2
No.1
No.2
No.3No.4No.5No.6
Number mark
12
22 33
1
Connecting rod cap
Crankshaft
Use bearing
EXAMPLE: Connecting rod cap º3º + Crankshaft º1º
= Total number 4 (Use bearing º4º)12 3
0120120
34 4 5 EM±78
± ENGINE MECHANICAL (2JZ±GE)CYLINDER BLOCK
1432 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
(i) Measure the Plastigage at its widest point.
Standard oil clearance:
STD0.023 ± 0.041 mm (0.0009 ± 0.0016 in.)
U/S 0.250.028 ± 0.066 mm (0.0011 ± 0.0026 in.)
Maximum oil clearance:
STD0.07 mm (0.0027 in.)
U/S 0.250.08 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.)
Standard sized 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.