lock LEXUS GS400 2000 Service Repair Manual

A02656
A02671
Timing MarkSub Timing Mark
60°
Turn
A02660
Dot
Mark
30°Timing
MarkDot
Mark
30°Timing
Mark
A02653
± ENGINE MECHANICAL (2JZ±GE)TIMING BELT
EM±17
1371 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
10. SET NO.1 CYLINDER TO APPROX. 60°/ BTDC COM-
PRESSION
(a) Turn the crankshaft pulley, and align its groove with timing
mark º0º of the No.1 timing belt cover.
NOTICE:
Always turn the crankshaft clockwise.
(b) Check that the timing marks (TDC mark) of the camshaft
timing pulleys are aligned with the timing marks of the
No.4 timing belt cover.
If not, turn the crankshaft 1 revolution (360°).
(c) Turn the crankshaft pulley 60° counterclockwise to place
the sub timing mark (60° mark BTDC) on the crankshaft
pulley at the timing mark º0º position of the No.1 timing
belt cover.
NOTICE:
If the timing belt is disengaged, having the crankshaft
pulley at the wrong angle can cause the piston head and
valve head to come into contact with each other when you
remove the camshaft timing pulleys (steps 11 to 17), thus
resulting damage. So, always set the crankshaft pulley at
the correct angle.
(d) Check that the dot marks (60° mark BTDC) of the cam-
shaft timing pulleys are aligned with the timing marks of
the No.4 timing belt cover.
(e) Remove the crankshaft pulley bolt.
NOTICE:
Do not turn the crankshaft pulley.
11. REMOVE TIMING BELT FROM CAMSHAFT TIMING
PULLEYS
HINT:
(Re±using timing belt):
Place matchmarks on the timing belt and camshaft timing pul-
leys as shown in the illustration.

EM0D7±03
EM0126
No!
P02283
Turn
P02075
± ENGINE MECHANICAL (2JZ±GE)TIMING BELT
EM±21
1375 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
INSPECTION
1. INSPECT TIMING BELT
NOTICE:

Do not bend, twist or turn the timing belt inside out.
Do not allow the timing belt to come into contact with
oil, water or steam.

Do not utilize timing belt tension when installing or re-
moving the mount bolt of the camshaft timing pulley.
If there are any defects, as shown in the illustrations, check the
following points.
(a) Premature parting

Check for proper installation.

Check the timing cover gasket for damage and
proper installation.
(b) If the belt teeth are cracked or damaged, check to see if
either camshaft is locked.
(c) If there is noticeable wear or cracks on the belt face,
check to see if there are nicks on the side of the idler
pulley lock.
(d) If there is wear or damage on only one side of the belt,
check the belt guide and the alignment of each pulley.
(e) If there is noticeable wear on the belt teeth, check timing
cover for damage and check gasket has been installed
correctly and for foreign material on the pulley teeth.
If necessary, replace the timing belt.
2. INSPECT IDLER PULLEY
(a) Visually check the seal portion of the idler pulley for oil
leakage.
If leakage is found, replace the idler pulley.
(b) Check the turning smoothness of the idler pulley.
If necessary, replace the idler pulley.
3. INSPECT DRIVE BELT TENSIONER
Check the turning smoothness of the tensioner.
If necessary, replace the tensioner.
4. INSPECT TIMING BELT TENSIONER
(a) Visually check tensioner for oil leakage.
HINT:
If there is only the faintest trace of oil on the seal on the push
rod side, the tensioner is all right.
If leakage is found, replace tensioner.

P10918
A02646
A02645
Turn
A02656
A02691
SST
± ENGINE MECHANICAL (2JZ±GE)TIMING BELT
EM±27
1381 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
16. INSTALL TIMING BELT TENSIONER
(a) Temporarily install the tensioner with the 2 bolts.
(b) Alternately tighten the 2 bolts.
Torque: 27 N´m (270 kgf´cm, 20 ft´lbf)
(c) Remove the 1.5 mm hexagon wrench from the tensioner
with pliers.
17. CHECK VALVE TIMING
(a) Slowly turn the crankshaft pulley 2 revolutions from TDC
to TDC.
NOTICE:
Always turn the crankshaft clockwise.
(b) Check that each pulley aligns with the timing marks as
shown in the illustration.
If the marks do not align, remove the timing belt and reinstall it.
18. TIGHTEN CRANKSHAFT PULLEY BOLT
Using SST, install the pulley bolt.
SST 09213±70010, 09330±00021
Torque: 330 N´m (3,300 kgf´cm, 243 ft´lbf)
19. INSTALL DRIVE BELT TENSIONER
Install the tensioner with the 3 bolts.
Torque: 21 N´m (210 kgf´cm, 15 ft´lbf)
NOTICE:
Be careful not to drop the bolts inside the timing belt cover.

S03016
Lift
Pry EM±38
± ENGINE MECHANICAL (2JZ±GE)CYLINDER HEAD
1392 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
(c) Lift the cylinder head from the dowels on the cylinder
block.
(d) Disconnect the heater hose from the heater union.
(e) Place the head on wooden blocks on a bench.
If the cylinder head is difficult to lift off, pry with a screwdriver be-
tween the cylinder head and block projection.
NOTICE:
Be careful not to damage the contact surfaces of the cylin-
der head and cylinder block.

EM0DC±03
A02682
A02683
A02705
A02706
P02072
EM±40
± ENGINE MECHANICAL (2JZ±GE)CYLINDER HEAD
1394 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
INSPECTION
1. CLEAN TOP SURFACES OF PISTONS AND
CYLINDER BLOCK
(a) Turn the crankshaft, and bring each piston to top dead
center (TDC). Using a gasket scraper, remove all the car-
bon from the piston top surface.
(b) Using a gasket scraper, remove all the gasket material
from the top surface of the cylinder block.
(c) Using compressed air, blow carbon and oil from the bolt
holes.
CAUTION:
Protect your eyes when using high ± pressure compressed
air.
2. CLEAN CYLINDER HEAD
(a) Remove the gasket material.
Using a gasket scraper, remove all the gasket material
from the cylinder block surface.
NOTICE:
Be careful not to scratch the cylinder block contact sur-
face.
(b) Clean the combustion chambers.
Using a wire brush, remove all the carbon from the com-
bustion chambers.
NOTICE:
Be careful not to scratch the cylinder block contact sur-
face.
(c) Clean the valve guide bushings.
Using a valve guide bushing brush and solvent, clean all
the guide bushings.

A02707
A02711P02145
P02135
P02144
A03796
A02708
EM0580
± ENGINE MECHANICAL (2JZ±GE)CYLINDER HEAD
EM±41
1395 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
(d) Clean the cylinder head.
Using a soft brush and solvent, thoroughly clean the cylin-
der head.
3. INSPECT CYLINDER HEAD
(a) Inspect for the flatness.
Using precision straight edge and feeler gauge, measure
the surfaces contacting the cylinder block, intake and ex-
haust manifolds for warpage.
Maximum warpage: 0.10 mm (0.0039 in.)
If warpage is greater than maximum, replace the cylinder head.
(b) Inspect for the cranks.
Using a dye penetrant, check the combustion chamber,
intake ports, exhaust ports and cylinder block surface for
cracks.
If cracked, replace the cylinder head.
4. CLEAN VALVES
(a) Using a gasket scraper, chip off any carbon from the valve
head.
(b) Using a wire brush, thoroughly clean the valve.

A02820
EM2011
EM2538
A02817
Plastigage
± ENGINE MECHANICAL (2JZ±GE)CYLINDER HEAD
EM±45
1399 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
9. INSPECT CAMSHAFTS FOR RUNOUT
(a) Place the camshaft on V±blocks.
(b) Using a dial indicator, measure the circle runout at the
center journal.
Maximum circle runout: 0.08 mm (0.0031 in.)
If the circle runout is greater than maximum, replace the cam-
shaft.
10. INSPECT CAM LOBES
Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
Intake44.310 ± 44.360 mm (1.7445 ± 1.7465 in.)
Exhaust44.250 ± 44.350 mm (1.7421 ± 1.7461 in.)
Minimum cam lobe height:
Intake44.16 mm (1.7386 in.)
Exhaust44.10 mm (1.7362 in.)
If the cam lobe height is less than minimum, replace the cam-
shaft.
11. INSPECT CAMSHAFT JOURNALS
Using a micrometer, measure the journal diameter.
Journal diameter:
28.949 ± 28.965 mm (1.1397 ± 1.1404 in.)
If the journal diameter is not as specified, check the oil clear-
ance.
12. INSPECT CAMSHAFT BEARING
Check the bearings for flaking and scoring.
If the bearings are damaged, replace the bearing caps and cyl-
inder head as a set.
13. INSPECT CAMSHAFT JOURNAL OIL CLEARANCE
(a) Clean the bearing caps and camshaft journals.
(b) Place the camshafts on the cylinder head.
(c) Lay a strip of Plastigage across each of the camshaft jour-
nals.
(d) Install the bearing caps. (See page EM±52)
Torque: 20 N´m (200 kgf´cm, 14 ft´lbf)
NOTICE:
Do not turn the camshaft.
(e) Remove the bearing caps.

A02638
A02651
A02664
EX
IN135
24
135
24 1 1
EM±6
± ENGINE MECHANICAL (2JZ±GE)VALVE CLEARANCE
1360 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
5. REMOVE NO.3 TIMING BELT COVER
Using a 5 mm hexagon wrench, remove the 4 bolts, oil filler cap,
timing belt cover and gasket.
6. REMOVE IGNITION COILS AND HIGH±TENSION
CORD SET ASSEMBLY (See page IG±7)
7. REMOVE SPARK PLUGS
8. DISCONNECT ENGINE WIRE FROM CYLINDER HEAD
COVERS
9. REMOVE CYLINDER HEAD COVERS
(See page EM±33)
10. SET NO.1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley and align its groove with the
timing mark º0º of the No.1 timing belt cover.
NOTICE:
Always turn the crankshaft clockwise.
(b) Check that the timing marks of the camshaft timing pul-
leys are aligned with the timing marks of the No.4 timing
belt cover.
If not, turn the crankshaft 1 revolution (360°).
11. INSPECT VALVE CLEARANCE
(a) Check only those valves indicated in the illustration.

Using a feeler gauge, measure the clearance be-
tween the valve lifter and camshaft.

Record the valve clearance measurements of those
that are out of specification. They will be used later
to determine the required replacement adjusting
shim.
Valve clearance (Cold):
Intake0.15 ± 0.25 mm(0.006 ± 0.010 in.)
Exhaust0.25 ± 0.35 mm (0.010 ± 0.014 in.)
(b) Turn the crankshaft pulley 1 revolution (360°), and align
the groove with the timing mark º0º of the No.1 timing belt
cover.

EM0DE±03
P02185
Adhesive Width
2 ± 3 mm
Adhesive
10 mm
Z08040
Protrusion
A02704
A02686
(e) (d) (c) (b)
EM±50
± ENGINE MECHANICAL (2JZ±GE)CYLINDER HEAD
1404 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 and oil seals with new ones.
1. INSTALL HEATER UNION
HINT:
When using a new cylinder head, a new heater union must be
installed.
(a) Apply adhesive to the end of the heater union as shown
in the illustration.
Adhesive: Part No.08833±00070, THREE BOND 1324
or equivalent
(b) Using a wooden block and hammer, tap in a new heater
union, leaving 48 mm (1.89 in.) protruding from the cylin-
der head.
NOTICE:
Do not tap it in too far.
2. INSTALL VALVES
(a) Install a new oil seal on the valve guide bushing.
(b) Install the valve.
(c) Install the spring seat.
(d) Install the valve spring.
(e) Install the spring retainer.

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.