intake LEXUS GS400 2000 Service Owner's Guide

EM0D2±04
A11131
(d) (g)
(f)
(e) (b)
(c)
A11130
(h)(i)
(j)
(k)
A11129
(o)
(n)
(o)
± ENGINE MECHANICAL (2JZ±GE)VALVE CLEARANCE
EM±5
1359 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
VALVE CLEARANCE
ADJUSTMENT
HINT:
Inspect and adjust the valve clearance when the engine is cold.
1. REMOVE ENGINE COVER
Remove the 4 nuts and engine cover.
2. DRAIN ENGINE COOLANT
3. REMOVE INTAKE AIR RESONATOR
4. REMOVE THROTTLE BODY AND INTAKE AIR
CONNECTOR ASSEMBLY
(a) Disconnect the accelerator cable from the throttle body.
(b) Disconnect the engine wire clamp from the clamp bracket
of the throttle body.
(c) Disconnect the engine wire from the clamp on the throttle
body bracket.
(d) Disconnect the accelerator pedal position sensor con-
nector.
(e) Disconnect the throttle control motor connector.
(f) Disconnect the throttle position sensor connector.
(g) Disconnect the air assist hose from the intake air connec-
tor.
(h) Disconnect the PCV hose from the intake air connector.
(i) Disconnect the VSV connector for EVAP.
(j) Disconnect the EVAP hose (from charcoal canister) from
the VSV for EVAP.
(k) Disconnect the vacuum hose (from No.2 vacuum pipe)
from the No.1 vacuum pipe.
(l) Remove the 2 nuts holding the throttle body bracket to the
cylinder head.
(m) Remove the 4 bolts and 2 nuts holding the intake air con-
nector to the air intake chamber.
(n) Disconnect the vacuum hose (from actuator for ACIS)
from the No.1 vacuum pipe.
(o) Disconnect the 2 water bypass hoses from the throttle
body, and remove the throttle body together with the in-
take air connector and gasket.

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.

A02666
SST (A) SST (B)
9
P10901
SST (B)
Magnetic Finger
EM0494
P11925
SST (A)
SST (B) EM±8
± ENGINE MECHANICAL (2JZ±GE)VALVE CLEARANCE
1362 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)

When the adjusting shim of the No.1 intake side replace,
remove the No.2 or No.3 camshaft bearing cap, and in-
sert SST as shown in the illustration.

Using a small screwdriver and a magnetic finger, remove
the adjusting shim.
(b) Determine the replacement adjusting shim size according
to the following formula or Charts:

Using a micrometer, measure the thickness of the
removed shim.

Calculate the thickness of a new shim so the valve
clearance comes within specified value.
T .......... Thickness of used shim
A .......... Measured valve clearance
N .......... Thickness of new shim
Intake
N = T + (A ± 0.20 mm (0.008 in.))
Exhaust
N = T + (A ± 0.30 mm (0.012 in.))

Select a new shim with a thickness as close as pos-
sible to the calculated values.
HINT:
Shims are available in 17 sizes in increments of 0.050 mm
(0.0020 in.), from 2.500 mm (0.0984 in.) to 3.300 mm (0.1299
in.).
(c) Install a new adjusting shim.

Place a new adjusting shim on the valve lifter, with
imprinted numbers facing down.

Press down the valve lifter with SST (A), and re-
move SST (B).
SST 09248±55040
13. REINSTALL CYLINDER HEAD COVERS
(See page EM±52)
14. RECONNECT ENGINE WIRE TO CYLINDER HEAD
COVERS

± ENGINE MECHANICAL (2JZ±GE)VALVE CLEARANCE
EM±9
1363 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
15. REINSTALL SPARK PLUGS
16. REINSTALL IGNITION COILS AND HIGH±TENSION
CORD SET ASSEMBLY (See page IG±9)
17. REINSTALL NO.3 TIMING BELT COVER
(a) Install the gasket to the timing belt cover.
(b) Using a 5 mm hexagon wrench, install the timing belt cov-
er with the 4 bolts.
Torque: 8.0 N´m (80 kgf´cm, 71 in.´lbf)
(c) Install the oil filler cap.
18. REINSTALL THROTTLE BODY AND INTAKE AIR CON-
NECTOR ASSEMBLY
(a) Install a new gasket to the air intake chamber.
(b) Place the throttle body together with the intake air con-
nector on the cylinder head.
(c) Connect the vacuum hose (from actuator for ACIS) to the
No.1 vacuum pipe.
(d) Connect the 2 water bypass hoses to the throttle body.
(e) Install the 4 bolts and 2 nuts holding the intake air connec-
tor to the air intake chamber.
Torque: 28 N´m (280 kgf´cm, 21 ft´lbf)
(f) Install the 2 nuts holding the throttle body bracket to the
cylinder head.
Torque: 21 N´m (210 kgf´cm, 15 ft´lbf)
(g) Connect the air assist hose to the intake air connector.
(h) Install the PCV hose to the intake air connector.
(i) Install the EVAP hose (from charcoal canister) to the VSV
for EVAP.
(j) Install the vacuum hose (from No.2 vacuum pipe) to the
No.1 vacuum pipe.
(k) Install the throttle position sensor connector.
(l) Install the accelerator pedal position sensor connector.
(m) Install the throttle control motor connector.
(n) Install the VSV connector for EVAP.
(o) Secure the engine wire with the clamp on the throttle body
bracket.
(p) Install the engine wire clamp with the clamp bracket of the
throttle body.
(q) Connect the accelerator cable to the throttle body.
19. REINSTALL INTAKE AIR RESONATOR
20. REINSTALL ENGINE COVER
Install the engine cover with the 4 nuts.
21. REFILL WITH ENGINE COOLANT
22. START ENGINE AND CHECK FOR LEAKS

V00719
Adjusting Shim Selection Chart (Intake)
Intake valve clearance (Cold):
0.15 ± 0.25 mm (0.006 ± 0.010 in.)
EXAMPLE: The 2.800 mm (0.1102 in.) shim is installed, and
the measured clearance is 0.450 mm (0.0177 in.).
Replace the 2.800 mm (0.1102 in.) shim with a new No.12 shim.New shim thickness mm (in.)
Shim
No. ThicknessThickness Shim
No.
HINT: New shims have the thickness
in millimeters imprinted on the face.
Installed Shim Thickness
mm (in.)
Measured Clearance
mm (in.)
EM±10
± ENGINE MECHANICAL (2JZ±GE)VALVE CLEARANCE
1364 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)

A02698
Seal Packing
A11122
A11123
± ENGINE MECHANICAL (2JZ±GE)CYLINDER HEAD
EM±55
1409 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
(b) Install the VV±i (intake camshaft timing) pulley.
(See page EM±23)
7. CONNECT TIMING BELT TO CAMSHAFT TIMING
PULLEYS (See page EM±23)
8. INSTALL NO.1 AND NO.2 CYLINDER HEAD COVERS
(a) Remove the any old packing (FIPG) material.
(b) Apply seal packing to the cylinder head as shown in the
illustration.
Seal packing: Part No. 08826±00080 or equivalent
(c) Install the gaskets to the cylinder head covers.
(d) Install the cylinder head covers with the 12 bolts and 4
nuts.
Torque: 8.5 N´m (85 kgf´cm, 75 in.´lbf)
9. INSTALL INTAKE MANIFOLD ASSEMBLY
(a) Install a new gasket and the intake manifold and delivery
pipe assembly with the 7 bolts and 2 nuts.
Torque: 28 N´m (280 kgf´cm, 21 ft´lbf)
(b) Pass the water bypass hose between the No.2, No.3 in-
take ports of the manifold and delivery pipe.
(c) Install the manifold stay with the 2 bolts.
Torque: 40 N´m (400 kgf´cm, 30 ft´lbf)
(d) Install the starter wire to the manifold stay.
10. INSTALL FUEL PRESSURE PULSATION DAMPER
(See page SF±27)
11. CONNECT ENGINE WIRE TO CYLINDER HEAD
(a) Install the engine wire protector with the 3 nuts.
(b) Using a 5 mm hexagon wrench, install the bolt holding the
engine wire protector to the No.2 cylinder head cover.
(c) Connect the 6 injector connectors.
HINT:
The Nos.1, 3, 5 injector connectors and dark gray, and the
Nos.2, 4, 6 injector connectors are brown.
(d) Connect the camshaft timing oil control valve connector.
(e) Connect the camshaft position sensor connector.
(f) Connect the ECT sensor connector.

A02733
Clamp Bracket
A02811
A02732
(v)(s)(t)
(u)(u)
(t)
(s) EM±56
± ENGINE MECHANICAL (2JZ±GE)CYLINDER HEAD
1410 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
(g) Connect the 2 knock sensor connector.
(h) Connect the starter connector.
(i) Connect the oil pressure switch connector.
(j) Connect the oil level sensor connector.
(k) Install the clamp bracket to the intake manifold.
(l) Connect the 2 wire clamps to the No.1 oil pipe and clamp
bracket on the intake manifold.
(m) Install the 2 ground terminals to the intake manifold.
Tighten so that each calking part should face inside.
(n) Install the clamp bracket to the water pump.
(o) Connect the generator connector.
(p) Connect the crankshaft position sensor connector.
(q) Connect the heated oxygen sensor (bank 1 sensor 1)
connector.
(r) Secure the engine wire with the clamp.
(s) Install the 2 hose clamps to the cylinder head and oil filter
bracket.
(t) Install the heated oxygen sensor (bank 2 sensor 1) con-
nector and engine wire clamp to the hose clamps.
(u) Install the 2 water bypass hoses to the hose clamps on
the cylinder head and oil filter bracket.
(v) Install the ground strap to the cylinder head.
12. INSTALL SPARK PLUGS
13. INSTALL IGNITION COILS AND HIGH±TENSION
CORD SET ASSEMBLY (See page IG±9)
14. INSTALL NO.3 TIMING BELT COVER
Torque: 8.0 N´m (80 kgf´cm, 71 in.´lbf)

A02735
A09752
A11121
Case Clamp
New Clamp
A02819
± ENGINE MECHANICAL (2JZ±GE)CYLINDER HEAD
EM±57
1411 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
15. INSTALL VACUUM CONTROL VALVE SET AND NO.2
VACUUM PIPE
(a) Install the vacuum control valve set and No.2 vacuum
pipe with the 3 nuts.
Torque: 21 N´m (210 kgf´cm, 15 ft´lbf)
(b) Install the engine wire clamp to the clamp bracket of the
No.2 vacuum pipe.
(c) Connect the VSV connector for the ACIS.
16. INSTALL AIR INTAKE CHAMBER (See page SF±49)
17. INSTALL OIL DIPSTICK AND GUIDE FOR A/T
(See page EM±68)
18. INSTALL OIL DIPSTICK AND GUIDE FOR ENGINE
(See page LU±12)
19. INSTALL THROTTLE BODY AND INTAKE AIR
CONNECTOR ASSEMBLY (See page EM±5)
20. INSTALL WATER BYPASS OUTLET AND NO.1 WATER
BYPASS PIPE (See page CO±13)
21. INSTALL EXHAUST MANIFOLD
(a) Install 2 new gaskets to the cylinder head.
(b) Using a 14 mm deep socket wrench, install the exhaust
manifold with the 8 nuts. Uniformly tighten the nuts in sev-
eral passes.
Torque: 40 N´m (408 kgf´cm, 30 ft´lbf)
(c) Connect the 3 heated oxygen sensor connectors and
clamp.
(d) Install a new clamp and the case clamp as shown in the
illustration.
22. CONNECT FRONT EXHAUST PIPE TO EXHAUST
MANIFOLD
(a) Temporarily install the pipe support bracket to the trans-
mission with the 2 bolts.
(b) Install 2 new gaskets to front end of the front exhaust pipe,
and connect the front exhaust pipe to the exhaust man-
ifold with the 3 bolts and nuts.
Torque: 44 N´m (440 kgf´cm, 32 ft´lbf)
(c) Tighten the 2 bolts holding the pipe support bracket to the
transmission.

B01935
Wire
Grommet
Clamp
A02802
EM±58
± ENGINE MECHANICAL (2JZ±GE)CYLINDER HEAD
1412 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
Torque: 44 N´m (440 kgf´cm, 32 ft´lbf)
(d) Connect the wire grommet and sensor wire of the the
heated oxygen sensor (bank 2 sensor 2) to the hole and
clamp on the floor.
23. INSTALL PS PUMP
(a) Install the vane pump with the 2 bolts.
Torque: 58 N´m (590 kgf´cm, 43 ft´lbf)
(b) Install the pump rear stay with the 2 bolts.
Torque: 39.2 N´m (400 kgf´cm, 29 ft´lbf)
(c) Connect the PS air hose to the No.4 timing belt cover.
(d) Connect the PS air hose to the air intake chamber.
24. INSTALL DRIVE BELT (See page CH±1)
25. INSTALL AIR CLEANER, MAF METER AND INTAKE
AIR RESONATOR ASSEMBLY (See page EM±68)
26. INSTALL AIR CLEANER INLET
27. CONNECT UPPER RADIATOR HOSE TO WATER OUT-
LET
28. INSTALL ENGINE COVER
Install the engine cover with the 4 nuts.
29. FILL WITH ENGINE COOLANT
30. START ENGINE AND CHECK FOR LEAKS
31. INSTALL ENGINE UNDER COVER
32. ROAD TEST
Check for abnormal noise, shock, slippage, correct shift points
and smooth operation.
33. RECHECK ENGINE COOLANT LEVEL

EM0DG±03
A09759
Air Cleaner,
MAF Meter and
Intake Air Resonator
Assembly
PCV Hose
Hood SupportHood
MAF Meter
Connector
Engine Wire
ClampWasher Hose
Accelerator Cable PS Air Hose
EVAP Hose
Air Cleaner Inlet
Radiator Lower Hose
Engine Under CoverFront Suspension
Member Brace x 6
x 18 Radiator Upper Hose
Upper Radiator
Drive Belt
ECM Outlet Duct
ECT Switch Connector
Connector
Radiator Assembly Radiator Lower Support
Oil Cooler Hose for A/TEVAP Hose
Heater
Hose
Support
Electric Cooling Fan Engine Cover
± ENGINE MECHANICAL (2JZ±GE)ENGINE UNIT
EM±59
1413 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
ENGINE UNIT
COMPONENTS