light LEXUS GS400 2000 Service Repair Manual

EM2534
Overall
Length
EM0255
A02709
45° Carbide Cutter
Z00373
Width
P03966
Width 45°
15°
± ENGINE MECHANICAL (2JZ±GE)CYLINDER HEAD
EM±43
1397 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
(d) Check the valve overall length.
Standard overall length:
Intake98.29 ± 98.79 mm (3.8697 ± 3.8894 in.)
Exhaust98.84 ± 99.34 mm (3.8913 ± 3.9110 in.)
Minimum overall length:
Intake98.19 mm (3.8657 in.)
Exhaust98.74 mm (3.8874 in.)
If the overall length is less than minimum, replace the valve.
(e) Check the surface of the valve stem tip for wear.
If the valve stem tip is worn, resurface the tip with a grinder or
replace the valve.
NOTICE:
Do not grind off more than the minimum overall length.
7. INSPECT AND CLEAN VALVE SEATS
(a) Using a 45° carbide cutter, resurface the valve seats.
Remove only enough metal to clean the seats.
(b) Check the valve seating position.
Apply a thin coat of Prussian blue (or white lead) to the
valve face. Lightly press the valve against the seat. Do not
rotate the valve.
(c) Check the valve face and seat for the following:

If blue appears 360° around the face, the valve is
concentric. If not, replace the valve.

If blue appears 360° around the valve seat, the
guide and face are concentric. If not, resurface the
seat.

Check that the seat contact is in the middle of the
valve face with the following width:
If not, correct the valve seats as follows:
Intake1.0 ± 1.4 mm (0.039 ± 0.055 in.)
Exhaust1.2 ± 1.6 mm (0.047 ± 0.063 in.)
(1) If the seating is too high on the valve face, use 15°
and 45° cutters to correct the seat.

A02665
EX
IN
35 24
35 24
66
66
P02094
Upward
Cam Lobe
Notch
P12860
EX Side
IN SideSST (B)
P12294
SST (A)
P11926
SST (A) SST (B)
7
± ENGINE MECHANICAL (2JZ±GE)VALVE CLEARANCE
EM±7
1361 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
(c) Check only the valves indicated as shown. Measure the
valve clearance. (See procedure in step (a))
12. ADJUST VALVE CLEARANCE
(a) Remove the adjusting shim.

Turn the camshaft so that the cam lobe for the valve
to be adjusted faces up.

Turn the valve lifter with a screwdriver so that the
notches are perpendicular to the camshaft.

Insert SST (B) gently from the inside as shown in the
illustration.

Using SST (A), hold the camshaft as shown in the
illustration.
SST 09248±55040 (09248±05410)

Using SST (A), press down the valve lifter and place
SST (B) between the camshaft and valve lifter. Re-
move SST (A).
SST 09248±55040 (09248±05410, 09248±05420)
HINT:

Apply SST (B) at slight angle on the side marked with º7º
or º9º, at the position shown in the illustration.

A02715
SST
A02702
± ENGINE MECHANICAL (2JZ±GE)CYLINDER HEAD
EM±51
1405 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
(f) Using SST, compress the valve spring and place the 2
keepers around the valve stem.
SST 09202±70020 (09202±00010)
(g) Using a plastic±faced hammer, lightly tap the valve stem
tip to assure proper fit.
3. INSTALL VALVE LIFTERS AND SHIMS
(a) Install the valve lifter and shim.
(b) Check that the valve lifter rotates smoothly by hand.
4. INSTALL ECT SENSOR
Torque: 19.6 N´m (200 kgf´cm, 14 ft´lbf)
5. INSTALL CAMSHAFT POSITION SENSOR
6. INSTALL ENGINE HANGER
Torque: 40 N´m (400 kgf´cm, 30 ft´lbf)
7. INSTALL WATER OUTLET WITH WATER BYPASS
HOSE
Install a new gasket and the water outlet with the bolt and 2
nuts.
Torque: 28 N´m (280 kgf´cm, 21 ft´lbf)

EM0DF±04
S02567
S02651
10 mm
Bi±Hexagon
Wrench
12 8 4 2 5 9 13
14 10 1161 3 7
S02643
Front90°
Painted Mark90°
90°
90°
A02699
Knock Pin
UpUp
EM±52
± ENGINE MECHANICAL (2JZ±GE)CYLINDER HEAD
1406 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
INSTALLATION
1. PLACE CYLINDER HEAD ON CYLINDER BLOCK
(a) Place a new cylinder head gasket in position on the cylin-
der block.
NOTICE:
Be sure to install it correctly.
(b) Place the cylinder head in position on the cylinder head
gasket.
2. INSTALL CYLINDER HEAD BOLTS
HINT:

The cylinder head bolts are tightened in 2 progressive
steps (steps (c) and (f)).

If any of bolts break or deform, replace them.
(a) Apply a light coat of engine oil on the threads and under
the heads of the cylinder head bolts.
(b) Install the 14 plate washers to each cylinder head bolt.
(c) Using a 10 mm bi±hexagon wrench, uniformly tighten the
cylinder head bolts, in several passes, in the sequence
shown.
Torque: 35 N´m (350 kgf´cm, 26 ft´lbf)
If any of the bolts do not meet the torque specification, replace
the bolt.
(d) Mark the front of the cylinder head bolt head with paint.
(e) Retighten the cylinder head bolts 90° in the numerical or-
der shown.
(f) Retighten cylinder head bolts by an additional 90° shown.
(g) Check that the painted mark is now turned to the rear.
3. INSTALL CAMSHAFTS
(a) Apply engine oil to the thrust portion of the camshaft.
(b) Place the camshaft on the cylinder head with the cam
lobe facing up as shown.

A02700
A02701
Front
Z17798
2 mm
Seal Width
1 ± 2 mm2 ± 3 mmSeal PackingNo.1
No.3Seal Packing
2 ± 3 mm
S03018
148
1226104
3
4
3 9
5
7
1
11
13
14
1312
112
18
76
510
9
± ENGINE MECHANICAL (2JZ±GE)CYLINDER HEAD
EM±53
1407 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
(c) Place the (Nos. 3, 7 journal) camshaft bearing caps in
their proper location.
(d) Apply a light coat of engine oil on the threads and under
the heads of the bearing cap bolts.
(e) Temporarily tighten these bearing cap bolts uniformly and
alternately, in several passes, until the bearing caps are
snug with the cylinder head.
(f) Apply MP grease to a new camshaft oil seal lip.
(g) Install the 2 oil seals to the camshafts.
(h) Clean the installed surfaces of the Nos.1, 3 camshaft
bearing cap and cylinder head with cleaner.
(i) Apply seal packing to the bearing caps as shown.
Seal packing: Part No. 08826±00080 or equivalent
(j) Install the other bearing caps in their proper locations.
(k) Apply a light coat of engine oil on the threads and under
the heads of the bearing cap bolts.
(l) Install and uniformly tighten the 14 bearing cap bolts on
one side, in several passes, in the sequence shown.
Torque: 20 N´m (200 kgf´cm, 15 ft´lbf)
(m) Using a 5 mm hexagon wrench, the 2 No.3 camshaft
bearing cap bolts.
Torque: 5.0 N´m (50 kgf´cm, 44 in.´lbf)

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)

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.

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.

R11910Match Marks
± INTRODUCTIONFOR ALL OF VEHICLES
IN±11
11 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
reset the memory. To avoid erasing the memory of
each memory system, never use a back±up power
supply from another battery.
(3) Even in cases of a minor collision where the SRS
does not deploy, the steering wheel pad, front pas-
senger airbag assembly, side airbag assembly,
front airbag sensor, side airbag sensor and seat belt
pretensioner should be inspected
(See page RS±15, RS±29, RS±42, RS±60, RS±65
and BO±125).
(4) Never use SRS parts from another vehicle. When
replacing parts, replace them with new parts.
(5) Before repairs, remove the airbag sensor if shocks
are likely to be applied to the sensor during repairs.
(6) Never disassemble and repair the airbag sensor as-
sembly, side airbag sensor assembly, steering
wheel pad, front passenger airbag assembly, side
airbag assembly, front airbag sensor, side airbag
sensor or seat belt pretensioner.
(7) If the airbag sensor assembly, side airbag sensor
assembly, steering wheel pad, front passenger air-
bag assembly, side airbag assembly, front airbag
sensor, side airbag sensor or seat belt pretensioner
has been dropped, or if there are cracks, dents or
other defects in the case, bracket or connector, re-
place them with new ones.
(8) Do not directly expose the airbag sensor assembly,
side airbag sensor assembly, steering wheel pad,
front passenger airbag assembly, side airbag as-
sembly, front airbag sensor, side airbag sensor or
seat belt pretensioner to hot air or flames.
(9) Use a volt/ohmmeter with high impedance (10 kW/V
minimum) for troubleshooting of the electrical cir-
cuit.
(10) Information labels are attached to the periphery of
the SRS components. Follow the instructions on the
notices.
(11) After work on the supplemental restraint system is
completed, check the SRS warning light (See page
DI±552).
(c) SPIRAL CABLE (in Combination Switch)
The steering wheel must be fitted correctly to the steering
column with the spiral cable at the neutral position, other-
wise cable disconnection and other troubles may result.
Refer to SR±17 of this manual concerning correct steer-
ing wheel installation.