LEXUS GS400 2000 Service Repair Manual

P04794
SST
Z02384
Cut Position
P04795
SST
P04475
P04796
SST
SST
± ENGINE MECHANICAL (2JZ±GE)CYLINDER BLOCK
EM±89
1443 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
(2) Using SST and a hammer, tap in a new oil seal until
its surface is flush with the oil pump body edge.
SST 09316±60011 (09316±00011)
(3) Apply MP grease to the oil seal lip.
(b) If the pump is installed on the cylinder block.
(1) Using a knife, cut off the oil seal lip.
(2) Using a screwdriver, pry out the oil seal.
NOTICE:
Be careful not to damage the crankshaft. Tape the screw-
driver tip.
(3) Apply MP grease to a new oil seal lip.
(4) Using SST and a hammer, tap in the oil seal until its
surface is flush with the oil pump body edge.
SST 09316±60011 (09316±00011)
3. REPLACE CRANKSHAFT REAR OIL SEAL
HINT:
There are 2 methods (a) and (b) to replace the oil seal as fol-
lows:
(a) If the rear oil seal retainer is removed from the cylinder
block.
(1) Using a screwdriver and hammer, tap out the oil
seal.
(2) Using SST and a hammer, tap in a new oil seal until
its surface is flush with the rear oil seal retainer
edge.
SST 09223±15030, 09950±70010 (09951±07100)
(3) Apply MP grease to the oil seal lip.

Z02416
Cut Position
P02363
SST EM±90
± ENGINE MECHANICAL (2JZ±GE)CYLINDER BLOCK
1444 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
(b) If the rear seal retainer is installed on the cylinder block.
(1) Using a knife, cut off the oil seal lip.
(2) Using a screwdriver, pry out the oil seal.
NOTICE:
Be careful not to damage the crankshaft. Tape the screw-
driver tip.
(3) Apply MP grease to a new oil seal lip.
(4) Using SST and a hammer, tap in the oil seal until its
surface is flush with the rear oil seal retainer edge.
SST 09223±15030, 09950±70010 (09951±07100)

EM0DN±03
A02737
A02681
Front
Mark
A02679 EM3123A03853
Code Mark
No.1
No.2Code Mark
A02672
Upper Side
Rail
Front Mark
(Cavity)
No.2
CompressionExpander
Lower Side
RailNo.1
Compression
± ENGINE MECHANICAL (2JZ±GE)CYLINDER BLOCK
EM±91
1445 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
REASSEMBLY
HINT:

Thoroughly clean all parts to be assembled.

Before installing the parts, apply fresh engine oil to all slid-
ing and rotating surfaces.

Replace all gaskets, O±rings and oil seals with new parts.
NOTICE:
Apply a generous amount of oil on the sliding surface of the
bearing, and not on the back of it or on the surface to which
it is installed.
1. ASSEMBLE PISTON AND CONNECTING ROD
(a) Using a small screwdriver, install a new snap ring on one
side of the piston pin hole.
HINT:
Be sure that end gap of the snap ring is not aligned with the pin
hole cutout portion of the piston.
(b) Gradually heat the piston to about 80°C (176°F).
(c) Coat the piston pin with engine oil.
(d) Align the front marks of the piston and connecting rod,
and push in the piston pin with your thumb.
(e) Install a new snap ring at the other end of the piston pin
hole.
HINT:
Be sure that end gap of the snap ring is not aligned with the pin
hole cutout portion of the piston.
2. INSTALL PISTON RINGS
(a) Install the oil ring expander and 2 side rails by hand.
(b) Using a piston ring expander, install the 2 compression
rings with the code mark facing up.
Code mark:
No.11T
No.22T
(c) Position the piston rings so that the ring ends are as
shown.
NOTICE:
Do not align the piston ring ends.

P02139
P04797
No.1Others
23.0 mm20.0 mm
A02723
P02671
A02754
EM±92
± ENGINE MECHANICAL (2JZ±GE)CYLINDER BLOCK
1446 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
3. INSTALL BEARINGS
(a) Align the bearing claw with the groove of the connecting
rod and connecting cap.
(b) Install the bearings in the connecting rod and connecting
rod cap.
4. INSTALL MAIN BEARINGS
HINT:

Main bearings come in widths of 20.0 mm (0.787 in.) and
23.0 mm (0.906 in.). Install the 23.0 mm bearings in the
No.1 cylinder block journal position with the main bearing
cap. Install the 20.0 mm bearings in the other positions.

Upper bearings have an oil groove and oil holes; lower
bearings do not.
(a) Align the bearing claw with the claw groove of the main
bearing cap or cylinder block.
NOTICE:
Install the bearing with the oil hole in the cylinder block.
(b) Install the bearings in the cylinder block and main bearing
caps.
5. INSTALL UPPER THRUST WASHERS
Install the 2 thrust washers under the No.4 main journal position
of the cylinder block with the oil grooves facing outward.
6. PLACE CRANKSHAFT ON CYLINDER BLOCK

P02430
P02160
P02284
11
7
1283
41
25
69
1013
14
P02440
90°Painted Mark
90°
P04472
± ENGINE MECHANICAL (2JZ±GE)CYLINDER BLOCK
EM±93
1447 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
7. PLACE MAIN BEARING CAP AND LOWER THRUST
WASHERS ON CYLINDER BLOCK
(a) Install the lower thrust washers on the No.4 main bearing
with the grooves facing outward.
(b) Install the main bearing caps in numerical order with the
arrows facing forward.
8. INSTALL MAIN BEARING CAP BOLTS
HINT:

The main bearing cap bolts are tightened in 2 progressive
steps (steps (b) and (d)).

If any of the main bearing bolts break or deform, replace
them.
(a) Apply a light coat of engine oil on the threads and under
the heads of the main bearing cap bolts.
(b) Install and uniformly tighten the 14 main bearing cap
bolts, in several passes, in the sequence shown.
Torque: 45 N´m (450 kgf´cm, 33 ft´lbf)
If any one of the main bearing cap bolts does not meet the
torque specification, replace the main bearing cap bolt.
(c) Mark the front of the main bearing cap bolt head with
paint.
(d) Retighten the main bearing cap bolts 90° in the numerical
order shown above.
(e) Check that the painted mark is now at a 90° angle to the
front.
(f) Check that the crankshaft turns smoothly.
9. 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.

A02747
Front Mark
(Cavity)
Front
P04479
P02426
EM±94
± ENGINE MECHANICAL (2JZ±GE)CYLINDER BLOCK
1448 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
Thrust washer thickness:
1.940 ± 1.990 mm (0.0764 ± 0.0783 in.)
10. INSTALL PISTON AND CONNECTING ROD
ASSEMBLIES
Using a piston ring compressor, push the correctly numbered
piston and connecting rod assemblies into each cylinder with
the front mark of the piston facing forward.
11. PLACE CONNECTING ROD CAP ON CONNECTING
ROD
(a) Match the numbered connecting rod cap with the con-
necting rod.
(b) Install the connecting rod cap with by aligning the dowel
pin to the corresponding hole.
12. INSTALL CONNECTING ROD CAP BOLTS
HINT:

The connecting rod cap bolts are tightened in 2 progres-
sive steps (steps (b) and (d)).

If any of the connecting rod bolts break or deform, replace
them.
(a) Apply a light coat of engine oil on the threads and under
the heads of the connecting rod cap bolts.
(b) Install and alternately tighten the bolts of the connecting
rod cap in several passes.
Torque: 30 N´m (300 kgf´cm, 22 ft´lbf)
If any one of the connecting rod cap bolts does not meet the
torque specification, replace the cap bolt.

P02420
Painted Mark
90°90°
P02197
Seal Width
2 ± 3 mm
Seal
Packing
± ENGINE MECHANICAL (2JZ±GE)CYLINDER BLOCK
EM±95
1449 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
(c) Mark the front of the connecting rod cap bolt with paint.
(d) Retighten the connecting rod cap bolts 90° in the numeri-
cal order shown.
(e) Check that the painted mark is now at a 90° angle to the
front.
(f) Check that the crankshaft turns smoothly.
13. CHECK CONNECTING ROD THRUST CLEARANCE
(See page EM±76)
14. INSTALL REAR OIL SEAL RETAINER
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the retainer
and cylinder block.

Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces and sealing groove.

Thoroughly clean all components to remove all de-
bris.

Using a non±residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the retainer as shown in the illustra-
tion.
Seal packing: Part No.08826±00080 or equivalent

Install a nozzle that has been cut to a 2 ± 3 mm (0.08
± 0.12 in.) opening.

Parts must be assembled within 3 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.

Immediately remove nozzle from the tube and rein-
stall cap.
(c) Install the retainer with the 6 bolts.
Torque: 6.0 N´m (60 kgf´cm, 53 in.´lbf)
15. INSTALL OIL PUMP (See page LU±12)
16. INSTALL RH ENGINE MOUNTING BRACKET AND
INSULATOR ASSEMBLY
Install the mounting bracket with the 4 bolts.
Torque: 59 N´m (590 kgf´cm, 44 ft´lbf)
17. INSTALL LH ENGINE MOUNTING BRACKET AND
INSULATOR ASSEMBLY
Install the mounting bracket with the 4 bolts.
Torque: 59 N´m (590 kgf´cm, 44 ft´lbf)
18. INSTALL FUEL INLET PIPE
Install the fuel inlet pipe with the 2 bolts.
Torque: 29 N´m (290 kgf´cm, 21 ft´lbf)
19. INSTALL NO.1 OIL PIPE
Install the No.1 oil pipe with 2 new gaskets and the union bolt.
Torque: 55 N´m (550 kgf´cm, 41 ft´lbf)

EM±96
± ENGINE MECHANICAL (2JZ±GE)CYLINDER BLOCK
1450 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
20. INSTALL OIL FILTER AND BRACKET ASSEMBLY
(a) Install a new O±ring to the oil filter bracket.
(b) Install a new gasket to the union bolt.
(c) Install the oil filter bracket with the union bolt.
Torque: 90 N´m (900 kgf´cm, 65 ft´lbf)
21. INSTALL OIL PRESSURE SWITCH AND KNOCK
SENSORS (See page LU±1, SF±63)
22. INSTALL CYLINDER HEAD (See page EM±52)
23. INSTALL WATER PUMP (See page CO±8)
24. INSTALL NO.2 WATER BYPASS PIPE WITH HOSE
(a) Install the water bypass pipe with the bolt and 2 nuts.
Torque: 21 N´m (210 kgf´cm, 15 ft´lbf)
(b) Connect the water bypass hose to the hose clamp.
25. INSTALL TIMING PULLEYS AND BELT
(See page EM±23)
26. INSTALL GENERATOR
Install the generator and pipe bracket with the bolt and nut.
Torque: 40 N´m (400 kgf´cm, 30 ft´lbf)
27. REMOVE ENGINE STAND FROM ENGINE

EM0DO±03
A09756

Before installing oxygen sensor, twist
sensor wire counterclockwise 3 and 1/2
turns.

After installing oxygen sensor, check that
sensor wire is not twisted. If it is twisted,
remove oxygen sensor and reinstall it.HINT:
Ring
RingRing BracketHeat Insulator
RH Tailpipe


Heat
Insulator

 
RingBracketRing Tailpipe
Baffle Gasket
Center Exhaust PIpe
 Gasket
Ring
Heat Insulator
LH Tailpipe
Tailpipe
Baffle
44 (440, 32)
44 (440, 32)
Front Floor
Center Brace
Heated Oxygen Sensor
Heated Oxygen Sensor
(Bank 2 Sensor 2)
Heat InsulatorHeat Insulator
45 (450, 33)
44 (440, 32)
 Gasket
N´m (kgf´cm, ft´lbf) : Specified torque
 Non±reusable partPipe Support Bracket
Front Exhaust Pipe
 Gasket Heat
Insulator
44 (440, 32)
± ENGINE MECHANICAL (2JZ±GE)EXHAUST SYSTEM
EM±97
1451 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
EXHAUST SYSTEM
COMPONENTS

IN00U±35
N17080
Filler Cap
Float
Reservoir Tank
 Grommet
Clip
Slotted Spring Pin
: Specified torque
 Non±reusable partCylinder
Piston
Push Rod
Washer
Snap Ring
Boot
 Gasket
Lock Nut
Clevis Pin
Clevis
N´m (kgf´cm, ft´lbf)
12 (120, 9)
15 (155, 11)
± INTRODUCTIONHOW TO USE THIS MANUAL
IN±1
1 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
HOW TO USE THIS MANUAL
GENERAL INFORMATION
1. INDEX
An INDEX is provided on the first page of each section to guide you to the item to be repaired. To assist you
in finding your way through the manual, the section title and major heading are given at the top of every page.
2. PRECAUTION
At the beginning of each section, a PRECAUTION is given that pertains to all repair operations contained
in that section.
Read these precautions before starting any repair task.
3. TROUBLESHOOTING
TROUBLESHOOTING tables are included for each system to help you diagnose the problem and find the
cause. The fundamentals of how to proceed with troubleshooting are described on page IN±21.
Be sure to read this before performing troubleshooting.
4. PREPARATION
Preparation lists the SST (Special Service Tools), recommended tools, equipment, lubricant and SSM (Spe-
cial Service Materials) which should be prepared before beginning the operation and explains the purpose
of each one.
5. REPAIR PROCEDURES
Most repair operations begin with an overview illustration. It identifies the components and shows how the
parts fit together.
Example: