lock LEXUS GS400 2000 Service Repair Manual

± BRAKETROUBLESHOOTING
BR±3
2111 Author: Date:
2000 LEXUS GS300/GS400 (RM718U) Noise from brakes
1. Pad (Cracked or distorted)
2. Installation bolt (Loose)
3. Disc (Scored)
4. Pad support plate (Loose)
5. Sliding pin (Worn)
6. Pad (Dirty)
7. Pad (Glazed)
8. Tension or return spring (Faulty)
9. Anti±squeal shim (Damaged)
10.Shoe hold±down spring (Damaged)BR±15
BR±24
BR±15
BR±24
BR±18
BR±27
BR±18
BR±18
BR±15
BR±24
BR±15
BR±24
BR±33
BR±18
BR±27
BR±33
Noise from hydraulic brake booster
(Abnormal pump motor operation noise)Accumulator bracket clearance (Out or adjustment)BR±56
Brake warning light lights up*1
(Parking brake pedal released)
1. Brake fluid level
2. Hydraulic brake booster power supply system (Faulty)BR±38
Brake warning light lights up and brake warning buzzer sounds*2Hydraulic brake booster power supply system (Faulty)BR±38
ABS warning light lights up*31. Anti±lock brake system (Faulty)
2. Hydraulic brake booster power supply system (Faulty)
BR±38
*1, *3: The light may stay on for about 60 seconds after the engine has been started. It is normal if it goes
out after a while.
*
2, *3: Depressing the brake pedal repeatedly may turn on the warning light and buzzer. It is normal if the
light goes out and the buzzer stops sounding after a few seconds.
*
3: While ABS warning light is ON, both VSC warning light and VSC OFF indicator light come on.

BR0JS±06
F01639
BR±28
± BRAKEREAR BRAKE CALIPER
2136 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
REMOVAL
1. REMOVE REAR WHEEL
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
2. DISCONNECT FLEXIBLE HOSE
Remove the union bolt and gasket from the caliper, then discon-
nect the flexible hose from the caliper. Use a container to catch
brake fluid as it drains out.
Torque: 30 N´m (310 kgf´cm, 22 ft´lbf)
HINT:
At the time of installation, please refer to the following item.
Install the flexible hose lock securely in the lock hole in the cali-
per.
3. REMOVE CALIPER
(a) Remove the 2 installation bolts.
Torque: 104 N´m (1,065 kgf´cm, 77 ft´lbf)
(b) Remove the caliper.
4. REMOVE BRAKE PADS (See page BR±25)
(a) Remove the anti±squeal spring.
(b) Remove the clip and pad guide pin.
(c) Remove the 2 pads with the 4 anti±squeal shims.

BR0K0±03
F02913
Contract
± BRAKEPARKING BRAKE
BR±37
2145 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See
page BR±34).
HINT:
Apply high temperature grease to the parts indicated by the ar-
rows (See page BR±33).
1. ADJUST PARKING BRAKE SHOE CLEARANCE
(a) Temporarily install the 3 hub nuts.
(b) Remove the hole plug.
(c) Turn the adjuster and expand the shoes until the disc
locks.
(d) Return the adjuster 8 notches.
(e) Install the hole plug.
2. SETTLING PARKING BRAKE SHOES AND DISC
(a) Depress the parking brake pedal with a force of 147 N (15
kgf, 33 lbf).
(b) Drive the vehicle at about 50 km/h (31 mph) on a safe, lev-
el and dry road.
(c) Drive the vehicle for about 400 meters (0.25 mile) in this
condition.
(d) Repeat this procedure 2 or 3 times.
3. CHECK AND ADJUST PARKING BRAKE PEDAL
TRAVEL (See page BR±11)

BR0K9±04
F06046
SST
F01655
SST
F06047
BR±50
± BRAKEHYDRAULIC BRAKE BOOSTER
2158 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
REMOVAL
NOTICE:

Before starting the work, make sure that the ignition
switch is OFF and depress the brake pedal more than
40 times.

As high pressure is applied to the brake actuator tube
No. 1, never deform it.

Until the work is over, do not turn the ignition switch
ON.
1. DRAW OUT FLUID WITH SYRINGE
NOTICE:
Do not let brake fluid remain on a painted surface. Wash it
off immediately.
2. REMOVE NO. 1 UNDER COVER (See page BO±88)
3. REMOVE END PAD AND NO. 1 SAFETY PAD
4. REMOVE NO. 7 HEATER TO REGISTER DUCT
5. DISCONNECT BRAKE LINES
Using SST, disconnect the 4 brake lines.
SST 09023±00100
Torque: 15 N´m (155 kgf´cm, 11 ft´lbf)
6. DISCONNECT LEFT FRONT WHEEL BRAKE LINE
Using SST, disconnect the left front wheel brake line from the
flexible hose.
SST 09023±00100
Torque: 15 N´m (155 kgf´cm, 11 ft´lbf)
7. REMOVE 2 BRAKE LINE CLAMPS
8. DISCONNECT LEVEL WARNING SWITCH CONNEC-
TOR
9. DISCONNECT 4 CONNECTORS
10. REMOVE PEDAL RETURN SPRING, CLIP AND CLE-
VIS PIN
11. REMOVE HYDRAULIC BRAKE BOOSTER ASSEMBLY
(a) Loosen the lock nut, then remove the clevis and lock nut.
Torque: 25 N´m (260 kgf´cm, 19 ft´lbf)
(b) Remove the 4 booster installation nuts.
Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)
(c) Remove the booster assembly and gasket.

F02847
Stop Light Switch
Push Rod
Pedal HeightBR0JB±07
F02849
Pedal Freeplay
± BRAKEBRAKE PEDAL
BR±9
2117 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
BRAKE PEDAL
ON±VEHICLE INSPECTION
1. CHECK PEDAL HEIGHT
Pedal height from asphalt sheet:
150.0 ± 160.0 mm (5.906 ± 6.299 in.)
2. IF NECESSARY, ADJUST PEDAL HEIGHT
(a) Remove the No. 1 under cover, end pad, No. 1 safety pad
and No. 7 heater to register duct (See page BO±88).
(b) Disconnect the connector from the stop light switch.
(c) Loosen the stop light switch lock nut and remove the stop
light switch.
(d) Loosen the push rod lock nut.
(e) Adjust the pedal height by turning the pedal push rod.
(f) Tighten the push rod lock nut.
Torque: 25 N´m (260 kgf´cm, 19 ft´lbf)
(g) Install the stop light switch.
(h) Push in the brake pedal 5 ± 15 mm (0.20 ± 0.59 in.), turn
the stop light switch to lock the nut in the position where
the stop light goes off.
(i) Connect the connector to the stop light switch.
(j) After installation, push in the brake pedal 5 ± 15 mm (0.20
± 0.59 in.), check that stop light lights up.
(k) After adjusting the pedal height, check the pedal freeplay.
(l) Install the No. 7 heater to register duct, No. 1 safety pad,
end pad and No. 1 under cover.
3. CHECK PEDAL FREEPLAY
(a) Stop the engine and depress the brake pedal more than
40 times until there is no more pressure left in the booster.
(b) Push in the pedal by hand until the second point of resis-
tance begins to be felt, then measure the distance, as
shown.
Pedal freeplay: 0.2 ± 2.0 mm (0.008 ± 0.079 in.)
If incorrect, check the stop light switch clearance. If the clear-
ance is OK, then troubleshoot the brake system.
Stop light switch clearance:
0.5 ± 2.4 mm (0.020 ± 0.094 in.)
HINT:
The freeplay to the 1st point of resistance is due to the play be-
tween the clevis and pin. It is 0.2 ± 2.0 mm (0.008 ± 0.079 in.)
on the pedal.

Z05962
B02027
Turn
B02028
Move
B01995
Type A
A
Type BB
AB
Z05963
CORRECT WRONG WRONG CH±2
± CHARGING (2JZ±GE)CHARGING SYSTEM
1604 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
5. INSPECT DRIVE BELT
HINT:
A belt tensioner is used, so checking the belt tension is not nec-
essary.
(a) Visually check the drive belt for excessive wear, frayed
cords, etc.
If necessary, replace the drive belt.
HINT:

Cracks on the rib side of a drive belt are considered ac-
ceptable. If the drive belt has chunks missing from the
ribs, it should be replaced.

The drive belt tension can be released by turning the belt
tensioner clockwise.
(b) Check the belt tensioner operation.

Check that the belt tensioner moves downward
when the drive belt is pressed down at the points in-
dicated in the illustration with approx. 98 N (10 kgf,
22.0 lbf) of force.

Check the alignment of the belt tensioner pulley to
make sure the drive belt will not slip off the pulley.
If necessary, replace the belt tensioner.

Check that the arrow mark on the belt tensioner falls
within area A of the scale.
If it is outside area A, replace the drive belt.
HINT:

When a new belt is installed, it should lie within area B. If
not, the drive belt is not correct.

After installing a drive belt, check that it fits properly in the
ribbed grooves.

Check by hand to confirm that the belt has not slipped out
of the groove on the bottom of the pulley.
6. VISUALLY CHECK GENERATOR WIRING AND
LISTEN FOR ABNORMAL NOISES
(a) Check that the wiring is in good condition.
(b) Check that there is no abnormal noise from the generator
while the engine is running.

CH049±01
P10639
Pulley
P10637
B02022
29 mm
Socket
Wrench
B01648
Wire
Clip
P10835
Turn
SST (B)SST (A)
± CHARGING (2JZ±GE)GENERATOR
CH±13
1615 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
REASSEMBLY
1. PLACE DRIVE END FRAME ON PULLEY
2. INSTALL ROTOR TO DRIVE END FRAME
3. INSTALL RECTIFIER END FRAME
(a) Place the generator washer on the rotor.
(b) Using a 29 mm socket wrench and press, slowly press in
the rectifier end frame.
(c) Install the 3 nuts.
Torque: 4.5 N´m (46 kgf´cm, 40 in.´lbf)
(d) Install the wire clip with the nut.
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
4. INSTALL PULLEY
(a) Install the pulley to the rotor shaft by tightening the pulley
nut by hand.
(b) Hold SST (A) with a torque wrench, and tighten SST (B)
clockwise to the specified torque.
SST 09820±63010
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
(c) Check that SST (A) is secured to the pulley shaft.

CH045±01
B02027
Turn
B01646
B01962
Engine
Wire Clamp
Pipe Clamp
B01963
Pipe Bracket
CH±6
± CHARGING (2JZ±GE)GENERATOR
1608 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
REMOVAL
1. REMOVE ENGINE UNDER COVER
2. REMOVE DRIVE BELT
Loosen the belt tension by turning the drive belt tensioner clock-
wise, and remove the drive belt.
NOTICE:
At the time of installation, please refer to the following
items. Do an on±vehicle inspection. (See page CH±1)
3. REMOVE GENERATOR
(a) Disconnect the generator connector.
(b) Remove the rubber cap and nut, and disconnect the gen-
erator wire.
(c) Disconnect the engine wire clamp from the wire clip on the
generator.
(d) Remove the bolt and pipe clamp, and disconnect the 2
A/T oil cooler pipes from the generator.
(e) Remove the bolt, nut, pipe bracket and generator.
Torque: 40 N´m (400 kgf´cm, 30 ft´lbf)

B01655
CH046±05
B01654
Plate Terminal
B01997
B01650
P10835
Turn
SST (B)SST (A)
± CHARGING (2JZ±GE)GENERATOR
CH±7
1609 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
DISASSEMBLY
1. REMOVE REAR END COVER
(a) Remove the nut and terminal insulator.
(b) Remove the bolt, 3 nuts, plate terminal and end cover.
2. REMOVE BRUSH HOLDER AND VOLTAGE REGULA-
TOR
(a) Remove the brush holder cover from the brush holder.
(b) Remove the 5 screws, brush holder and voltage regulator.
(c) Remove the seal plate from the rectifier end frame.
3. REMOVE RECTIFIER HOLDER
(a) Remove the 4 screws and rectifier holder.
(b) Remove the 4 rubber insulators.
4. REMOVE PULLEY
(a) Hold SST (A) with a torque wrench, and tighten SST (B)
clockwise to the specified torque.
SST 09820±63010
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
(b) Check that SST (A) is secured to the rotor shaft.

CO0A7±01
CO1242
Radiator Cap Tester
Radiator Cap
30° or More
B01882
Radiator Cap Tester
± COOLING (2JZ±GE)RADIATOR
CO±15
1553 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
ON±VEHICLE INSPECTION
1. REMOVE RADIATOR CAP
Remove the radiator cap from the radiator.
CAUTION:
To avoid the danger of being burned, do not remove the ra-
diator cap while the engine and radiator are still hot, as fluid
and steam can be blown out under pressure.
2. INSPECT RADIATOR CAP
NOTICE:

If the radiator cap has contaminations, always rinse
it with water.

Before using a radiator cap tester, wet the relief valve
and pressure valve with engine coolant or water.

When performing steps (a) and (b) below, keep the
tester at an angle of over 30° above the horizontal.
(a) Using a radiator cap tester, slowly pump the tester and
check that air is coming from the vacuum valve.
Pump speed: 1 push/(3 seconds or more)
NOTICE:
Push the pump at a constant speed.
If air is not coming from the vacuum valve, replace the radiator
cap.
(b) Pump the radiator cap tester, and measure the relief valve
opening pressure.
Pump speed: 1 push within 1 second
NOTICE:
This pump speed is for the first pump only (in order to close
the vacuum valve). After this, the pump speed can be re-
duced.
Standard opening pressure:
93 ± 123 kPa (0.95 ± 1.25 kgf/cm
2, 13.5 ± 17.8 psi)
Minimum opening pressure:
78 kPa (0.8 kgf/cm
2, 11.4 psi)
HINT:
Use the tester's maximum reading as the opening pressure.
If the opening pressure is less than minimum, replace the radia-
tor cap.
3. INSPECT COOLING SYSTEM FOR LEAKS
(a) Fill the radiator with coolant and attach a radiator cap tes-
ter.
(b) Warm up the engine.
(c) Pump it to 118 kPa (1.2 kgf/cm
2, 17.1 psi), and check that
the pressure does not drop.
If the pressure drops, check the hoses, radiator or water pump
for leaks. If no external leaks are found, check the heater core,
cylinder block and head.
4. REINSTALL RADIATOR CAP