intake LEXUS GS400 2000 Service User Guide

A11128
Accelerator Pedal Position Sensor Connector
Throttle Control Motor Connector
Throttle Body and Intake Air Connector Assembly
Water Bypass HoseVSV Connector
for EVAP
EVAP Hose
 Gasket Air Assist Hose Engine Wire
Oil Filler Cap
No.3 Timing Belt Cover
Gasket
No.2 Timing Belt Cover
GasketThrottle
Position
Sensor
Connector
Vacuum Hose
(from Actuator for ACIS)
Water Bypass Hose
Engine Wire Protector
High±Tension
Cord w/ Clamp
No.1 Cylinder
Head Cover
Gasket
Timing Belt
x 6
Timing Belt Guide
Gasket
x 5 No.1 Timing Belt Cover
Crankshaft
Pulley
21 (210, 15)
Drive Belt Tensioner
330 (3,300, 243)
Camshaft
Timing Pulley
(VVT±i Pulley)81 (810, 60)
Straight
Screw Plug
15 (150, 11)Seal Washer
Camshaft
Timing Oil
Control Valve
Camshaft Timing
Oil Control
Valve Connector Gasket
Oil Control Valve Filter
 O±Ring
No.1 Oil PipeUnion Bolt
55 (550, 41)
Idler Pulley
Crankshaft Timing Pulley
Timing Belt Plate
Timing Belt Tensioner
N´m (kgf´cm, ft´lbf) : Specified torque
35 (350, 26)

8.0 (80, 71 in.´lbf)
27 (270, 20)
 Non±reusable part

Precoated part
Dust Boot
Engine Wire ClampPCV Hose
Vacuum Hose
(from No.2
Vacuum Pipe)
± ENGINE MECHANICAL (2JZ±GE)TIMING BELT
EM±15
1369 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)

P11002
A11127
SST
A11126
5 mm
Hexagon
Wrench
A02662
Gasket
Union Bolt
Oil Control
Valve Filter
EM±18
± ENGINE MECHANICAL (2JZ±GE)TIMING BELT
1372 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
(a) Alternately loosen the 2 bolts, and remove them, the ten-
sioner and dust boot.
(b) Disconnect the timing belt from the camshaft timing pul-
leys.
12. REMOVE EXHAUST CAMSHAFT TIMING PULLEY
Using SST, remove the bolt and timing pulley.
SST 09960±10010 (09962±01000, 09963±01000)
13. REMOVE ENGINE COVER
Remove the 4 nuts and engine cover.
14. REMOVE THROTTLE BODY AND INTAKE AIR
CONNECTOR ASSEMBLY (See page EM±5)
15. REMOVE NO.1 CYLINDER HEAD COVER
(a) Using a 5 mm hexagon wrench, remove the bolts, and dis-
connect the engine wire protector from the No.2 cylinder
head cover.
(b) Remove the nut, and disconnect the engine wire protec-
tor from the intake manifold.
(c) Remove the 2 bolts, and disconnect the high±tension
cords with the clamp from the No.2 cylinder head.
(d) Remove the 6 bolts, 2 nuts, No.1 cylinder head cover and
gasket.
16. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE
(See page SF±43)
17. DISCONNECT NO.1 OIL PIPE
Remove the bolt, union bolt, oil control valve filter and 2 gas-
kets, and disconnect the No.1 oil pipe from the No.3 camshaft
bearing cap.

A02655
Drain Hole
Rotate
(30°)
DO NOT
REMOVE
A02650
Hold
Straight
Screw
PlugSet Bolt
Seal Washer
Hexagon Wrench
A02745
SST
Bolt
± ENGINE MECHANICAL (2JZ±GE)TIMING BELT
EM±19
1373 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
18. REMOVE VVT±i (INTAKE CAMSHAFT TIMING)
PULLEY
NOTICE:

The 5 bolts shown in the illustration determine the
backlash of the gear in the timing pulley, so do not re-
move them.
If any of the 5 bolts are removed, install a new cam-
shaft timing pulley assembly.

When removing the straight screw plug, follow the
prescribed procedure in order to avoid spilling oil on
the timing system parts.
(a) Rotate the VVT±i pulley from left to right 2 to 3 times within
its range of movement (30°) and use a waste cloth to col-
lect the oil from the camshaft timing oil control valve instal-
lation hole.
NOTICE:
Approximately 20 cc (1.2 cu in.) of oil will be ejected, so
take care not to spill it.
(b) Holding the hexagon portion of camshaft with a wrench.
(c) Using a 14 mm hexagon wrench, remove the straight
screw plug and seal washer.
NOTICE:
Some oil may spill, so put a waster cloth below the plug
white doing the operation.
(d) Using a 10 mm hexagon wrench, and remove the set bolt
and VVT±i pulley.
(e) Remove the wrench.
19. REMOVE CRANKSHAFT PULLEY
Using SST and bolt (diameter: 8 mm, pitch: 1.5 mm), remove
the crankshaft pulley.
SST 09950±50012 (09951±05010, 09552±05010,
09553±05020, 09554±05030)
Bolt: Part No. 90119±18001
NOTICE:
Do not turn the crankshaft pulley.
20. REMOVE NO.1 TIMING BELT COVER
Remove the 5 bolts, timing belt cover and gasket.
21. REMOVE TIMING BELT GUIDE

A02643
A02657
60°45°
15° (Set Key Groove Angle)
Timing Mark
Sub
Timing
Mark
A02648
Align
A02659
30° EM±24
± ENGINE MECHANICAL (2JZ±GE)TIMING BELT
1378 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
4. INSTALL TIMING BELT GUIDE
Install the guide, facing the cup side outward.
5. INSTALL NO.1 TIMING BELT COVER
(a) Install the gasket to the timing belt cover.
(b) Install the timing belt cover with the 5 bolts.
Torque: 8.0 N´m (80 kgf´cm, 71 in.´lbf)
6. INSTALL CRANKSHAFT PULLEY
(a) Align the pulley set key with the key groove of the pulley,
and slide on the pulley.
(b) Check that the sub timing mark (60° mark BTDC) of the
crankshaft pulley is aligned with the timing mark º0º of the
No.1 timing belt cover.
HINT:
At this time, the crankshaft pulley set key groove and the timing
mark (TDC mark) of the crankshaft pulley are as shown the il-
lustration.
(c) Temporarily install the pulley bolt.
7. INSTALL VVT±i (INTAKE CAMSHAFT TIMING)
PULLEY
(a) Align the camshaft knock pin with the VVT±i pulley, and
push the VVT±i pulley by hand until you feel it touch the
bottom.
(b) Check that the outer circumference of the VVT±i pulley
easily rotates through 30°.

A02726
Seal WasherSet BoltHold
Straight
Screw
Plug
A02722
Mesh Part
Frame Part
A11126
5 mm
Hexagon
Wrench
A02661
Front MarkSST
± ENGINE MECHANICAL (2JZ±GE)TIMING BELT
EM±25
1379 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
(c) Holding the hexagon portion of the camshaft with a
wrench.
(d) Using a 10 mm hexagon wrench, and the set bolt.
Torque: 81 N´m (810 kgf´cm, 60 ft´lbf)
(e) Using a 14 mm hexagon wrench, install the straight screw
plug with the seal washer to the set bolt.
Torque: 15 N´m (150 kgf´cm, 11 ft´lbf)
(f) Align the dot mark on the camshaft timing pulley with the
timing mark of the No.4 timing belt cover.
(g) Remove the wrench.
8. CONNECT NO.1 OIL PIPE
(a) Install the union bolt to the oil control valve filter.
NOTICE:
In case of touching the filter, avoid holding the mesh part
and holding the frame part.
(b) Install the oil pipe with 2 new gasket and the union bolt to
the No.3 camshaft bearing cap.
Torque: 55 N´m (550 kgf´cm, 41 ft´lbf)
9. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE
(See page SF±43)
10. INSTALL NO.1 CYLINDER HEAD COVER
(a) Install the cylinder head and gasket with the 6 bolts and
2 nuts.
Torque: 8.5 N´m (85 kgf´cm, 75 in.´lbf)
(b) Install the high±tension cords and clamps with the 2 bolts.
Torque: 8.0 N´m (80 kgf´cm, 71 in.´lbf)
(c) Using a 5 mm hexagon wrench, install the engine wire
protector with the bolt and nut.
11. INSTALL THROTTLE BODY AND INTAKE AIR
CONNECTOR ASSEMBLY (See page EM±5)
12. INSTALL ENGINE COVER
Install the engine cover with the 4 nuts.
13. INSTALL EXHAUST CAMSHAFT TIMING PULLEY
(a) Align the camshaft knock pin with the groove on the
pulley, and slide on the timing pulley.
(b) Slide the timing pulley on the camshaft, facing the front
mark forward.
(c) Using SST, install the pulley bolt.
SST 09960±10010 (09962±01000, 09963±01000)
Torque: 81 N´m (810 kgf´cm, 60 ft´lbf)

A02821
AlignSST
Turn
A02653
A02654
Z02446
1.5 mm
Hexagon
Wrench
P04459
EM±26
± ENGINE MECHANICAL (2JZ±GE)TIMING BELT
1380 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
(d) Using SST, align the dot mark on the camshaft timing tim-
ing pulley with the timing mark of the No.4 timing belt cov-
er.
SST 09960±10010 (09962±01000, 09963±01000)
14. CONNECT TIMING BELT TO CAMSHAFT TIMING
PULLEYS
HINT:
When re±using timing belt:

Check that the matchmark on the timing belt matches the
end of the No.1 timing belt cover.
If the matchmark does not align, shift the meshing of the
timing belt and crankshaft timing pulley until they align.

Align the matchmarks of the timing belt and camshaft tim-
ing pulleys.
(a) Remove any oil or water on the camshaft timing pulley,
and keep it clean.
(b) Install the timing belt, checking the tension between the
crankshaft timing pulley and intake camshaft timing
pulley.
15. SET TIMING BELT TENSIONER
(a) Using a press, slowly press in the push rod using 981 ±
9,807 N (100 ± 1,000 kgf, 220 ± 2,205 lbf) of force.
(b) Align the holes of the push rod and housing, pass a 1.5
mm hexagon wrench through the holes to keep the push
rod retracted.
(c) Release the press.
(d) Install the dust boot onto the tensioner.

EM0D9±04
A09751
Air Cleaner,
MAF Meter
and Intake Air
Resonator
Assembly
PCV HoseExhaust Manifold
Case Clamp
PS Air
Hose
EVAP Hose
Air Cleaner InletMAF Meter
Connector
Heated Oxygen Sensor
Connector
 Clamp
40 (408, 32)
x 8
 Gasket
44 (440, 32)
44 (440, 32)
Pipe Support Bracket
Accelerator Cable
 Gasket
Upper Radiator
Hose
Front Exhaust Pipe
Drive Belt
Engine Under Cover
x 18
N´m (kgf´cm, ft´lbf) : Specified torque
 Non±reusable Part
Engine Cover
± ENGINE MECHANICAL (2JZ±GE)CYLINDER HEAD
EM±29
1383 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
CYLINDER HEAD
COMPONENTS

A11125
Throttle Body and Intake Air Connector AssemblyWater Bypass Hose
PCV Hose
EVAP Hose
 Gasket
Air Assist Hose
Vacuum
Hose
PS Air Hose
Air Intake Chamber
Engine Wire
Clamp
Drive Belt
TensionerClamp Bracket
Ground StrapFuel Pressure
Pulsation Damper Clamp Bracket
Water Bypass
Outlet
No.1 Water Bypass Pipe
No.3 Timing Belt Cover O±Ring
Oil Filler CapFuel Inlet Pipe
PS Air Hose
Hose
Clamp
Timing Belt
Tensioner
PS Pump Stay
Oil Dipstick
and Guide
for A/T
PS Vane Pump Water Bypass Hose
28 (280, 21)
Engine Wire
 O±Ring
No.2 Timing Belt Cover
GasketGasket
21 (210, 15)
32.5 (325, 24)
 Gasket
 Gasket
Engine Wire
Clamp
 O±Ring  O±RingOil Dipstick and
Guide for Engine
27 (270, 20)
58 (590, 43)39.2 (400, 29)N´m (kgf´cm, ft´lbf) : Specified torque
 Non±reusable Part
Dust BootEngine Wire
Clamp
No.2 Vacuum Pipe
Hose Clamp
Vacuum Control
Valve Set
EM±30
± ENGINE MECHANICAL (2JZ±GE)CYLINDER HEAD
1384 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)

A11124
Ignition Coils and
High±Tension Cord
Assembly
GasketNo.2 Cylinder Head Cover
Camshaft Timing Oil Control ValveExhaust Camshaft
No.1 Camshaft Bearing Cap
Gasket
No.1 Cylinder Head Cover
No.2 Camshaft Bearing Cap x 6
x 24 x 6
20 (200, 15)
20 (200, 15)
Intake Camshaft
 O±Ring
 GasketOil Control Valve Filter
x 14 No.3 Camshaft Bearing Cap
No.1 Oil Pipe
See page EM±52
1st 35 (350, 25)
2nd Turn 90°
3rd Turn 90°
Heater Hose
55 (550, 41)
Union Bolt
18 (180, 13)Spark Plug
 Oil Seal
No.4 Timing Belt Cover
Camshaft Timing Pulley
Cylinder Head Assembly
Intake Manifold Assembly
Manifold Stay
 Cylinder Head Gasket
 Gasket
x 7
81 (810, 60)
15 (150, 11)
8.0 (80, 71 in.´lbf)
N´m (kgf´cm, ft´lbf) : Specified torque
 Non±reusable partx 12
28 (280, 21)
Starter Wire
Straight
Screw Plug
Timing Belt
± ENGINE MECHANICAL (2JZ±GE)CYLINDER HEAD
EM±31
1385 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)

EM0DA±03
A02823
A02802
B01935
Wire
Grommet
Clamp
± ENGINE MECHANICAL (2JZ±GE)CYLINDER HEAD
EM±33
1387 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
REMOVAL
1. REMOVE ENGINE UNDER COVER
2. DRAIN ENGINE COOLANT
3. DISCONNECT UPPER RADIATOR HOSE FROM WA-
TER OUTLET
4. REMOVE ENGINE COVER
Remove the 4 nuts and engine cover.
5. REMOVE AIR CLEANER INLET
6. REMOVE AIR CLEANER, MAF METER AND INTAKE
AIR RESONATOR ASSEMBLY (See page EM±62)
7. REMOVE DRIVE BELT (See page CH±1)
8. DISCONNECT PS PUMP WITHOUT DISCONNECTING
HOSES
(a) Disconnect the PS air hose from the No.4 timing belt cov-
er.
(b) Disconnect the PS air hose from the air intake chamber.
(c) Remove the 2 bolts and pump rear stay.
(d) Remove the 2 bolts, and disconnect the vane pump from
the pump bracket.
HINT:
Put aside the vane pump, and suspend it.
9. DISCONNECT FRONT EXHAUST PIPE FROM EX-
HAUST MANIFOLD
(a) Disconnect the wire grommet and sensor wire of the
heated oxygen sensor (bank 2 sensor 2) from the hole
and clamp on the floor.