LEXUS GS400 2000 Service Repair Manual

A02684
Z07401
412
8141062
371113951
P04472
P04471
± ENGINE MECHANICAL (2JZ±GE)CYLINDER BLOCK
EM±79
1433 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
17. 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.

Keep the bearings, connecting rod and cap togeth-
er.

Arrange the piston and connecting rod assemblies
in correct order.
18. 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.)
19. 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.

P04792
Plastigage
P04468
A02784
Mark
0, 1, 2, 3, 4,
5, 6 or 7
1, 2, 3, 4 or 5Mark
0, 1, 2, 3, 4,
5, 6 or 7 No.1
No.5No.6
No.2
No.3
No.4No.7
No.1
No.2
Mark No.3
No.4No.5No.6No.7 (A)
(B)
Cylinder block (A)
Crankshaft (B) =+Total number º º : Number mark
Use bearing0±2 3±5 6±8 9±11 12±14
º2º º3º º1º º5ºº4º
EXAMPLE: Cylinder block º3º (A)
+ Crankshaft º4º (B)
= Total number 7 (Use bearing º3º) EM±80
± ENGINE MECHANICAL (2JZ±GE)CYLINDER BLOCK
1434 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
(g) Lay a strip of Plastigage across each journal.
(h) Install the main bearing caps. (See page EM±91)
Torque:
1st 45 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 procedures (a) and (b) above)
(j) Measure the Plastigage at its widest point.
Standard clearance:
STD0.026 ± 0.040 mm (0.0010 ± 0.0016 in.)
U/S 0.250.025 ± 0.061 mm (0.0010 ± 0.0024 in.)
Maximum clearance:
STD0.06 mm (0.0024 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 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.

Crankshaft
number markCylinder block number mark
EXAMPLE: Cylinder block º3º Crankshaft º4º
= Use bearing º3º0
1
2
3
4
5
6
7012 3 4567
111
22
23
3
1122 23 3 3
1222 33 3 4
2223 33 4 4
2233 34 4 4
233 44344
33 4 43555
34435555
± ENGINE MECHANICAL (2JZ±GE)CYLINDER BLOCK
EM±81
1435 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
Standard sized bearing selection chart:
Reference
Cylinder block main journal bore diameter (A):
Mark º0º66.020 ± 66.022 mm (2.59922 ± 2.59929 in.)
Mark º1º66.022 ± 66.024 mm (2.59929 ± 2.59936 in.)
Mark º2º66.024 ± 66.026 mm (2.59936 ± 2.59944 in.)
Mark º3º66.026 ± 66.028 mm (2.59944 ± 2.59952 in.)
Mark º4º66.028 ± 66.030 mm (2.59952 ± 2.59960 in.)
Mark º5º66.030 ± 66.032 mm (2.59960 ± 2.59968 in.)
Mark º6º66.032 ± 66.034 mm (2.59968 ± 2.59976 in.)
Mark º7º66.034 ± 66.036 mm (2.59976 ± 2.59984 in.)
Crankshaft main journal diameter (B):
Mark º0º61.998 ± 62.000 mm (2.44086 ± 2.44094 in.)
Mark º1º61.996 ± 61.998 mm (2.44078 ± 2.44086 in.)
Mark º2º61.994 ± 61.996 mm (2.44070 ± 2.44078 in.)
Mark º3º61.992 ± 61.994 mm (2.44063 ± 2.44070 in.)
Mark º4º61.990 ± 61.992 mm (2.44055 ± 2.44063 in.)
Mark º5º61.988 ± 61.990 mm (2.44047 ± 2.44055 in.)
Mark º6º61.986 ± 61.988 mm (2.44039 ± 2.44047 in.)
Mark º7º61.984 ± 61.986 mm (2.44031 ± 2.44039 in.)
Standard bearing center wall thickness:
Mark º1º1.994 ± 1.997 mm (0.0785 ± 0.0786 in.)
Mark º2º1.997 ± 2.000 mm (0.0786 ± 0.0787 in.)
Mark º3º2.000 ± 2.003 mm (0.0787 ± 0.0789 in.)
Mark º4º2.003 ± 2.006 mm (0.0789 ± 0.0790 in.)
Mark º5º2.006 ± 2.009 mm (0.0790 ± 0.0791 in.)
(k) Completely remove the Plastigage.

P02292
A02673
A02679
A02674
P02278
EM±82
± ENGINE MECHANICAL (2JZ±GE)CYLINDER BLOCK
1436 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
20. REMOVE CRANKSHAFT
(a) Lift out the crankshaft
(b) Remove the upper bearings and upper thrust washers
from the cylinder block.
HINT:
Arrange the main bearing caps, bearings and thrust washers in
the correct order.
21. CHECK FIT BETWEEN PISTON AND PISTON PIN
Try to move the piston back and forth on the piston pin.
If any movement is felt, replace the piston and pin as a set.
22. REMOVE PISTON RINGS
(a) Using a piston ring expander, remove the 2 compression
rings.
(b) Remove the 2 side rails and oil ring expander by hand.
HINT:
Arrange the piston rings in correct order only.
23. DISCONNECT CONNECTING ROD FROM PISTON
(a) Using a small screwdriver, remove the 2 snap rings.
(b) Gradually heat the piston to about 80°C (176°F).
(c) Using a plastic±faced hammer and brass bar, lightly tap
out the piston pin and remove the connecting rod.
HINT:

The piston and pin are a matched set.

Arrange the pistons, pins, rings, connecting rods and
bearings in the correct order.

EM0DL±03
A02685
Z02380
P02286
EM0365
1 Thrust Direction
2 Axial Direction1
2
A
B
C10 mm (0.39 in.)
Middle
10 mm (0.39 in.)
A02684
± ENGINE MECHANICAL (2JZ±GE)CYLINDER BLOCK
EM±83
1437 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
INSPECTION
1. CLEAN CYLINDER BLOCK
(a) Remove gasket material
Using a gasket scraper, remove all the gasket material
from the cylinder block surface.
(b) Clean cylinder block
Using a soft brush and solvent, thoroughly clean the cylin-
der block.
2. INSPECT CYLINDER BLOCK SURFACE FOR
FLATNESS
Using precision straight edge and feeler gauge,
measure the top surfaces of the cylinder block for warpage.
Maximum warpage: 0.07 mm (0.0028 in.)
If warpage is greater than maximum, replace the cylinder block.
3. INSPECT CYLINDER FOR VERTICAL SCRATCHES
Visually check the cylinder for vertical scratches.
If deep scratches are present, replace the cylinder block.
4. INSPECT CYLINDER BORE DIAMETER
Using a cylinder gauge, measure the cylinder bore diameter at
positions A, B and C in the thrust and axial directions.
Standard diameter:
86.000 ± 86.013 mm (3.3858 ± 3.3863 in.)
Maximum diameter:
86.02 mm (3.3866 in.)
If the diameter is greater than maximum, replace the cylinder
block.
5. REMOVE CYLINDER RIDGE
If the wear is less than 0.2 mm (0.008 in.), using a ridge reamer,
grind the top of the cylinder.

A02827
About
50 mm
Compressed
Thread
A02675
A02676
A02677
34 mm EM±84
± ENGINE MECHANICAL (2JZ±GE)CYLINDER BLOCK
1438 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
6. INSPECT MAIN BEARING CAP BOLTS
Using vernier calipers, measure the minimum diameter of the
compressed thread at the measuring point.
Standard diameter:
9.96 ± 9.97 mm (0.3921 ± 0.3925 in.)
Minimum diameter:
9.7 mm (0.382 in.)
If the diameter is less than minimum, replace the bolt.
7. CLEAN PISTON
(a) Using a gasket scraper, remove the carbon from the pis-
ton top.
(b) Using a groove cleaning tool or broken ring, clean the pis-
ton ring grooves.
(c) Using solvent and a brush, thoroughly clean the piston.
NOTICE:
Do not use a wire brush.
8. INSPECT PISTON OIL CLEARANCE
(a) Using a micrometer, measure the piston diameter at right
angles to the piston pin center line, 34 mm (1.34 in.) from
the piston head.
Piston diameter:
85.945 ± 85.965 mm (3.3837 ± 3.3844 in.)
(b) Measure the cylinder bore diameter in the thrust direc-
tions. (See step 4)
(c) Subtract the piston diameter measurement from the cylin-
der bore diameter measurement.
Standard oil clearance:
0.035 ± 0.068 mm (0.0014 ± 0.0027 in.)
Maximum oil clearance:
0.10 mm (0.0039 in.)
If the oil clearance is greater than maximum, replace all the 6
pistons. If necessary, replace the cylinder block.

A02678
Z09736
105 mm
EM7639
A02680
± ENGINE MECHANICAL (2JZ±GE)CYLINDER BLOCK
EM±85
1439 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
9. INSPECT PISTON RING GROOVE CLEARANCE
Using a feeler gauge, measure the clearance between new pis-
ton ring and the wall of the piston ring groove.
Ring groove clearance:
No.10.011 ± 0.070 mm (0.0004 ± 0.0028 in.)
No.20.030 ± 0.070 mm (0.0012 ± 0.0028 in.)
If the clearance is not as specified, replace the piston.
10. INSPECT PISTON RING END GAP
(a) Insert the piston ring into the cylinder bore.
(b) Using a piston, push the piston ring a little beyond the bot-
tom of the ring travel, 105 mm (4.13 in.) from the top of the
cylinder block.
(c) Using a feeler gauge, measure the ring end gap.
Standard ring end gap:
No.10.300 ± 0.470 mm (0.0118 ± 0.0185 in.)
No.20.350 ± 0.520 mm (0.0138 ± 0.0205 in.)
Oil (Side rail)0.130 ± 0.450 mm (0.0051 ± 0.0177 in.)
Maximum ring end gap:
No.11.07 mm (0.0421 in.)
No.21.12 mm (0.0441 in.)
Oil (Side rail)1.05 mm (0.0413 in.)
If the end gap is greater than maximum, replace the piston ring.
If the end gap is greater than maximum, even with a new piston
ring, replace the cylinder block.
11. INSPECT PISTON PIN FIT
At 80°C (176°F), you should be able to push the piston pin into
the piston pin hole with your thumb.

Z02381
Z02382
P02275
EM0227
EM±86
± ENGINE MECHANICAL (2JZ±GE)CYLINDER BLOCK
1440 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
12. INSPECT CONNECTING ROD ALIGNMENT
Using a feeler gauge and rod aligner, check the connecting rod
alignment.

Check for out±of±alignment
Maximum out±of±alignment:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If out±of±alignment is greater than maximum, replace the con-
necting rod assembly.

Check for twist
Maximum twist:
0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
If twist is greater than maximum, replace the connecting rod as-
sembly.
13. INSPECT PISTON PIN OIL CLEARANCE
(a) Using a caliper gauge, measure the inside diameter of the
connecting rod bushing.
Bushing inside diameter:
22.005 ± 22.014 mm (0.8663 ± 0.8667 in.)
(b) Using a micrometer, measure the piston pin diameter.
Piston pin diameter:
21.997 ± 22.006 mm (0.8660 ± 0.8664 in.)
(c) Subtract the piston pin diameter measurement from the
bushing in side diameter measurement.
Standard oil clearance:
0.005 ± 0.011 mm (0.0002 ± 0.0004 in.)
Maximum oil clearance:
0.05 mm (0.0020 in.)
If the oil clearance is greater than maximum, replace the bush-
ing. If necessary, replace the piston and piston pin as a set.

P02459
About
20 mmCompressed
P02153
Z02383
± ENGINE MECHANICAL (2JZ±GE)CYLINDER BLOCK
EM±87
1441 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
14. INSPECT CONNECTING ROD BOLTS
Using vernier calipers, measure the minimum diameter of the
compressed bolt at the measuring point.
Standard diameter: 8.1 ± 8.3 mm (0.319 ± 0.327 in.)
Minimum diameter: 8.0 mm (0.315 in.)
If the diameter is less than minimum, replace the connecting rod
bolt.
15. INSPECT CRANKSHAFT FOR RUNOUT
(a) Place the crankshaft on V±blocks.
(b) Using a dial indicator, measure the circle runout at the
center journal.
Maximum circle runout: 0.06 mm (0.0024 in.)
If the circle runout is greater than maximum, replace the crank-
shaft.
16. INSPECT MAIN JOURNALS AND CRANK PINS
(a) Using a micrometer, measure the diameter of each main
journal and crank pin.
Main journal diameter:
STD61.984 ± 62.000 mm (2.4403 ± 2.4409 in.)
U/S 0.2561.745 ± 61.755 mm (2.4309 ± 2.4313 in.)
Crank pin diameter:
STD51.982 ± 52.000 mm (2.0465 ± 2.0472 in.)
U/S 0.2551.745 ± 51.755 mm (2.0372 ± 2.0376 in.)
If the diameter is not as specified, check the oil clearance.
(See page EM±76)
(b) Check each main journal and crank pin for taper and out±
of±round as shown.
Maximum taper and out±of round:
0.02 mm (0.0008 in.)
If the taper or out±of±round is greater than maximum, grind or
replace the crankshaft.
17. IF NECESSARY, GRIND AND HONE MAIN
JOURNALS AND/OR CRANK PINS

Grind and hone the main journals and/or crank pins to the
finished undersized diameter (See procedure step 16).

Install new main journal and/or crank pin undersized
bearings.

P04793
SST
EM0DM±03
P04799
Oil Hole
EM6535
P02143
P04473
EM±88
± ENGINE MECHANICAL (2JZ±GE)CYLINDER BLOCK
1442 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
REPLACEMENT
1. REPLACE CONNECTING ROD BUSHING
(a) Using SST and a press, press out the bushing.
SST 09222±30010
(b) Align the oil holes of a new bushing and the connecting
rod.
(c) Using SST and a press, press in the bushing.
SST 09222±30010
(d) Using a pin hole grinder, bore the bushing to obtain the
standard specified clearance (See page EM±83) be-
tween the bushing and piston pin.
(e) Check the piston pin fit at room temperature.
Coat the piston pin with engine oil and push it into the con-
necting rod with your thumb.
2. REPLACE CRANKSHAFT FRONT OIL SEAL
HINT:
There are 2 methods (a) and (b) to replace the oil seal as fol-
lows:
(a) If the oil pump is removed form the cylinder block.
(1) Using a screwdriver, pry out the oil seal.