LEXUS GS400 2000 Service Repair Manual

A11122
A02713
A02836
S03013
A02647
EM±36
± ENGINE MECHANICAL (2JZ±GE)CYLINDER HEAD
1390 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
22. REMOVE INTAKE MANIFOLD ASSEMBLY
(a) Disconnect the starter wire from the manifold stay.
(b) Remove the 2 bolts and manifold stay.
(c) Remove the 7 bolts, 2 nuts, intake manifold and delivery
pipe assembly and gasket.
23. REMOVE NO.1 AND NO.2 CYLINDER HEAD COVERS
(a) Remove the 12 bolts and 4 nuts.
(b) Remove the cylinder head covers and gaskets.
24. DISCONNECT TIMING BELT FROM CAMSHAFT TIM-
ING PULLEYS (See page EM±16)
NOTICE:

Support the timing belt, so that the measuring of the
crankshaft timing pulley and timing belt does not
shift.

Be careful not to drop anything inside the timing belt
cover.

Do not allow the timing belt to come into contact with
oil, water or dust.
25. REMOVE CAMSHAFT TIMING PULLEYS
(a) Remove the exhaust camshaft timing pulley.
Hold the hexagon portion of the camshaft with a wrench, and
remove the pulley bolt and camshaft pulley.
(b) Remove the VVT±i (intake camshaft timing) pulley.
(See page EM±16)
26. REMOVE NO.4 TIMING BELT COVER
Remove the 4 bolts and timing belt cover.

A02695
5 mm Hexagon
Wrench
A02696
No.1
No.3
A02930
110
211
12
5
67
83
49
1
2
11
12
5
6
7
8
3
4910
S02650
10 mm
Bi±Hexagon
Wrench
3
14 12 13 10 11 762
15 9 8 4
± ENGINE MECHANICAL (2JZ±GE)CYLINDER HEAD
EM±37
1391 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
27. REMOVE CAMSHAFTS
(a) Using a 5 mm hexagon wrench, the 2 No.3 camshaft
bearing cap bolts.
(b) Uniformly loosen and remove the 4 camshaft bearing cap
bolts.
(c) Using a screwdriver, pry out the Nos.1, 3 camshaft bear-
ing caps and oil seals.
NOTICE:
Be careful not to damage the cap. Tape the screwdriver tip.
(d) Uniformly loosen and remove the 12 camshaft bearing
cap bolts, in several passes, in the sequence shown.
(e) Remove the 6 No.2 camshaft bearing caps and camshaft.
Remove the intake and exhaust camshafts.
28. REMOVE CYLINDER HEAD ASSEMBLY
(a) Using a 10 mm bi±hexagon wrench, uniformly loosen and
remove the 14 cylinder head bolts, in several passes, in
the sequence shown.
NOTICE:
Cylinder head warpage or cranking could result from re-
moving in incorrect order.
(b) Remove the 14 plate washers.

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.

EM0DB±01
A02703
A02715
SST
± ENGINE MECHANICAL (2JZ±GE)CYLINDER HEAD
EM±39
1393 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
DISASSEMBLY
1. REMOVE WATER OUTLET WITH WATER BYPASS
HOSE
Remove the 2 nuts, bolt, water outlet and gasket.
2. REMOVE ENGINE HANGER
3. REMOVE CAMSHAFT POSITION SENSOR
4. REMOVE ECT SENSOR
5. REMOVE VALVE LIFTERS AND SHIMS
HINT:
Store the valve lifters and shims in correct order.
6. REMOVE VALVES
(a) Using SST, compress the valve spring and remove the 2
keepers.
SST 09202±70020 (09202±00010)
(b) Remove the spring retainer, valve spring, valve and
spring seat.
HINT:
Store the valves, valve springs, spring seats and spring retain-
ers in correct order.
(c) Using needle±nose pliers, remove the oil seal.

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.

Z02413
Z00052
Z00054
44.5°
EM0181
Margin Thickness EM±42
± ENGINE MECHANICAL (2JZ±GE)CYLINDER HEAD
1396 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
5. INSPECT VALVE STEMS AND GUIDE BUSHINGS
(a) Using a caliper gauge, measure the inside diameter of the
guide bushing.
Bushing inside diameter:
6.010 ± 6.030 mm (0.2366 ± 0.2374 in.)
(b) Using a micrometer, measure the diameter of the valve
stem.
Valve stem diameter:
Intake5.970 ± 5.985 mm (0.2350 ± 0.2356 in.)
Exhaust5.965 ± 5.980 mm (0.2348 ± 0.2354 in.)
(c) Subtract the valve stem diameter measurement from the
guide bushing inside diameter measurement.
Standard oil clearance:
Intake0.025 ± 0.060 mm (0.0010 ± 0.0024 in.)
Exhaust0.030 ± 0.065 mm (0.0012 ± 0.0026 in.)
Maximum oil clearance:
Intake0.08 mm (0.0031 in.)
Exhaust0.10 mm (0.0039 in.)
If the clearance is greater than maximum, replace the valve and
guide bushing. (See page EM±48)
6. INSPECT AND GRIND VALVES
(a) Grind the valve enough to remove pits and carbon.
(b) Check that the valve is ground to the correct valve face
angle.
Valve face angle: 44.5°
(c) Check the valve head margin thickness.
Standard margin thickness:
0.8 ± 1.2 mm (0.031 ± 0.047 in.)
Minimum margin thickness:
0.5 mm (0.020 in.)
If the margin thickness is less than minimum, replace the valve.

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.

Z02456Width 75°
45°
A02710
Z02457
Deviation
EM0801
EM0281
EM±44
± ENGINE MECHANICAL (2JZ±GE)CYLINDER HEAD
1398 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
(2) If the seating is too low on the valve face, use 75°
and 45° cutters to correct the seat.
(d) Hand±lap the valve and valve seat with an abrasive com-
pound.
(e) After hand±lapping, clean the valve and valve seat.
8. INSPECT VALVE SPRINGS
(a) Using a steel square, measure the deviation of the valve
spring.
Maximum deviation: 2.0 mm (0.079 in.)
If deviation is greater than maximum, replace the valve spring.
(b) Using vernier calipers, measure the free length of the
valve spring.
Free length:
Pink painted mark43.71 mm (1.7209 in.)
Yellow painted mark44.10 mm (1.7362 in.)
If the free length is not as specified, replace the valve spring.
(c) Using a spring tester, measure the tension of the valve
spring at the specified installed length.
Installed tension:
186.2 ± 205.8 N (19.0 ± 21.0 kgf, 41.9 ± 46.3 lbf)
at 34.5 mm (1.358 in.)
If the installed tension is not as specified, replace the valve
spring.

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.