intake LEXUS GS400 2000 Service Workshop Manual

SS±6
± SERVICE SPECIFICATIONSENGINE MECHANICAL (2JZ±GE)
162 Author: Date:
2000 LEXUS GS300/GS400 (RM718U) Valve (cont'd)
Stem oil clearance STD Intake
Exhaust
Maximum Intake
Exhaust
Margin thickness STD
Minimum0.025 ± 0.060 mm (0.0010 ± 0.0024 in.)
0.030 ± 0.065 mm (0.0012 ± 0.0026 in.)
0.08 mm (0.0031 in.)
0.10 mm (0.0039 in.)
0.8 ± 1.2 mm (0.031 ± 0.047 in.)
0.5 mm (0.020 in.)
Valve springDeviation Maximum
Free lengthPink painted mark
Yellow painted mark
Installed tension at 34.5 mm (1.358 in.)2.0 mm (0.079 in.)
43.71 mm (1.7209 in.)
44.10 mm (1.7362 in.)
186.2 ± 205.8 N (19.0 ± 21.0 kgf, 41.9 ± 46.3 lbf)
Valve lifterLifter diameter
Lifter bore diameter
Oil clearance STD
Maximum30.966 ± 30.976 mm (1.2191 ± 1.2195 in.)
31.000 ± 31.016 mm (1.2205 ± 1.2211 in.)
0.024 ± 0.050 mm (0.0009 ± 0.0020 in.)
0.07 mm (0.0028 in.)
CamshaftThrust clearance STD
Maximum
Cam lobe height STD Intake
Exhaust
Maximum Intake
Exhaust
Journal diameter
Journal oil clearance STD
Maximum
Circle runout Maximum0.080 ± 0.190 mm (0.0031 ± 0.0075 in.)
0.30 mm (0.0118 in.)
44.310 ± 44.360 mm (1.7445 ± 1.7465 in.)
44.250 ± 44.350 mm (1.7421 ± 1.7461 in.)
44.16 mm (1.7386 in.)
44.10 mm (1.7362 in.)
28.949 ± 28.965 mm (1.1397 ± 1.1404 in.)
0.035 ± 0.072 mm (0.0014 ± 0.0028 in.)
0.10 mm (0.0039 in.)
0.08 mm (0.0031 in.)
Air intake
chamberWarpage Maximum0.15 mm (0.0059 in.)
ManifoldWarpageMaximum Intake
Exhaust0.15 mm (0.0059 in.)
0.50 mm (0.0196 in.)
Cylinder blockCylinder head surface warpage Maximum
Cylinder bore diameter STD
Maximum
Main bearing bolt diameter STD
Minimum0.07 mm (0.0028 in.)
86.000 ± 86.013 mm (3.3858 ± 3.3863 in.)
86.02 mm (3.3866 in.)
9.96 ± 9.97 mm (0.3921 ± 0.3925 in.)
9.7 mm (0.382 in.)
Connecting
rodThrust clearance STD
Maximum
Connecting bolt diameter STD
Minimum
Connecting rod oil clearance STD STD
U/S 0.25
Maximum STD
U/S 0.25
Connecting rod bearing center wall thickness
(Reference) STD Mark 1
Mark 2
Mark 3
Mark 4
Mark 5
Bushing inside diameter
Piston pin diameter
Piston pin oil clearance STD
Maximum
Rod out ± of alignment Maximum per 100 mm (3.94 in.)
Rod twist Maximum per 100 mm (3.94 in.)0.250 ± 0.402 mm (0.0098 ± 0.0158 in.)
0.50 mm (0.0197 in.)
8.1 ± 8.3 mm (0.319 ± 0.327 in.)
8.0 mm (0.315 in.)
0.023 ± 0.041 mm (0.0009 ± 0.0016 in.)
0.028 ± 0.066 mm (0.0011 ± 0.0026 in.)
0.07 mm (0.0027 in.)
0.08 mm (0.0031 in.)
1.498 ± 1.501 mm (0.0590 ± 0.0591 in.)
1.501 ± 1.504 mm (0.0591 ± 0.0592 in.)
1.504 ± 1.507 mm (0.0592 ± 0.0593 in.)
1.507 ± 1.510 mm (0.0593 ± 0.0594 in.)
1.510 ± 1.513 mm (0.0594 ± 0.0596 in.)
22.005 ± 22.014 mm (0.8663 ± 0.8667 in.)
21.997 ± 22.006 mm (0.8660 ± 0.8664 in.)
0.005 ± 0.011 mm (0.0002 ± 0.0004 in.)
0.05 mm (0.0020 in.)
0.05 mm (0.0020 in.)
0.15 mm (0.0059 in.)

SS0FI±01
SS±8
± SERVICE SPECIFICATIONSENGINE MECHANICAL (2JZ±GE)
164 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
No.3 timing belt cover x Cylinder head8.08071 in.´lbf
Intake air connector x Air intake chamber2828021
Throttle body bracket x Cylinder head2121015
Timing belt plate x Oil pump8.08071 in.´lbf
Idler pulley x Oil pump3535026
No.1 timing belt cover x Oil pump8.08071 in.´lbf
Camshaft timing pulley x Camshaft8181060
Straight screw plug x Camshaft timing pulley1515011
No.1 oil pipe x No.3 camshaft bearing cap5555041
Cylinder head cover x Cylinder head8.58575 in.´lbf
High±tension cord x Cylinder head cover8.08071 in.´lbf
Timing belt tensioner x Oil pump2727020
Crankshaft pulley x Crankshaft3303,300243
Drive belt tensioner x Cylinder head2121015
No.2 timing belt cover x Cylinder head8.08071 in.´lbf
PS pump front bracket x PS vane pump5859043
PS pump front bracket x Cylinder block5253038
Camshaft bearing cap x Cylinder head2020014
ECT sensor x Cylinder head19.620014
Engine hanger x Cylinder head4040030
Water outlet x Cylinder head2828021
Cylinder head x Cylinder head 1st
2nd
3rd35
Turn 90°
Turn 90°350
Turn 90°
Turn 90°26
Turn 90°
Turn 90°
No.3 camshaft bearing cap x Cylinder head Hexagon bolt5.05044 in.´lbf
No.4 timing belt cover x Cylinder head8.08071 in.´lbf
Cylinder head cover x Cylinder head8.58575 in.´lbf
Intake manifold x Cylinder head2828021
Manifold stay x Intake manifold4040030
Manifold stay x Cylinder block4040030
Vacuum control valve set x Intake manifold2121015
Exhaust manifold x Cylinder head4040830
Front exhaust pipe x Exhaust manifold4444032
Pipe support bracket x Transmission4444032
PS vane pump x Cylinder block57.959043
PS vane pump x A/C compressor57.959043
PS pump rear stay x PS pump bracket39.240029
PS pump rear stay x Manifold stay39.240030
Engine hanger x Cylinder head4040030
Rear support member x Body25.526019
Drive plate x Crankshaft8385061
Transmission x Cylinder block7273053
Starter x Transmission3738027
No.1 oil pan x Transmission3738027

P09286
New O±ring
CORRECT
WRONG Grommet
Injector
Delivery Pipe
B01575
O±Ring Delivery Pipe
Grommet
Spacer Insulator
O±Ring
B02046
Push
B02045
Push Pull
SF±4
± SFI (2JZ±GE)SFI SYSTEM
1470 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
(c) Observe these precautions when removing and installing
the injectors.
(1) Never reuse the O±ring.
(2) When placing a new O±ring on the injector, take
care not to damage it in any way.
(3) Coat a new O±ring with spindle oil or gasoline be-
fore installing±never use engine, gear or brake oil.
(d) Install the injector to the delivery pipe and intake manifold
as shown in the illustration.
Before installing the injector, must apply spindle oil or gas-
oline on the place where a delivery pipe or an intake man-
ifold touches an O±ring of the injector.
(e) Observe these precautions when disconnecting the fuel
tube connector (quick type):
(1) Check if there is any dirt like mud on the pipe and
around the connector before disconnecting them
and clean the dirt away.
(2) Be sure to disconnect with hands.
(3) When the connector and the pipe are stuck, push
and pull the connector to free to disconnect and pull
it out. Do not use any tool at this time.
(4) Inspect if there is any dirt or the likes on the seal sur-
face of the disconnected pipe and clean it away.
(5) Prevent the disconnected pipe and connector from
damaging and mixing foreign objects by covering
them with a vinyl bag.
(f) Observe these precautions when connecting the fuel
tube connector (quick type):
(1) Check if there is any damage or foreign objects on
the connected part of the pipe.
(2) Match the axis of the connector with axis of the pipe,
and push in the connector until the connector
makes a ºclickº sound. In case the connections is
tight, apply little amount of new engine oil on the tip
of the pipe.

SF0NB±04
B01579
± SFI (2JZ±GE)INJECTOR
SF±21
1487 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
REMOVAL
1. REMOVE ENGINE COVER
Remove the 4 nuts and engine cover.
2. REMOVE AIR INTAKE CHAMBER (See page SF±46)
3. REMOVE FUEL PRESSURE PULSATION DAMPER
(See page SF±26)
4. REMOVE DELIVERY PIPE AND INJECTORS
NOTICE:

Be careful not to drop the injectors when removing
the delivery pipe.

Pay attention to put any hung load on the injector to
and from the side direction.
(a) Disconnect the 6 injector connectors.
(b) Disconnect the camshaft position sensor connector.
(c) Disconnect the throttle position sensor connector.
(d) Disconnect the VSV connector for EVAP.
(e) Remove the 3 bolts and delivery pipe together with the 6
injectors.
(f) Pull out the 6 injectors from the delivery pipe.
(g) Remove the O±rings, grommet and insulator from each
injector.
(h) Remove the 3 spacers from the intake manifold.

SF0ND±04
B01220
New Insulator
New O±Ring
New Grommet New O±Ring
B01571
Turn
Outward
Connector
B01580
RotateUpward SF±24
± SFI (2JZ±GE)INJECTOR
1490 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
INSTALLATION
1. INSTALL INJECTORS AND DELIVERY PIPE
(a) Install new insulator and grommet to each injector.
(b) Apply a light coat of spindle oil or gasoline to 2 new O±
rings and install them to each injector.
(c) Apply a light coat of spindle oil or gasoline on the place
where a delivery pipe touches an O±ring of the injector.
(d) While turning the injector clockwise and counterclock-
wise, push it to the delivery pipe. Install the 6 injectors.
(e) Position the injector connector outward.
(f) Place the 3 spacers in position on the intake manifold.
(g) Apply a light coat of spindle oil or gasoline on the place
where a intake manifold touches an O±ring of the injector.
(h) Place the 6 injectors together with the delivery pipe and
3 bolts in position on the intake manifold.
(i) Temporarily install the 3 bolts holding the delivery pipe to
the intake manifold.
(j) Check that the injectors rotate smoothly.
HINT:
If injectors do not rotate smoothly, the probable cause is incor-
rect installation of O±rings. Replace the O±rings.
(k) Position the injector connector upward.
(l) 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.
(m) Tighten the 3 bolts holding the delivery pipe to the intake
manifold.
Torque: 21 N´m (210 kgf´cm, 15 ft´lbf)
(n) Connect the camshaft position sensor connector.
(o) Connect the throttle position sensor connector.
(p) Connect the VSV connector for EVAP.
2. INSTALL FUEL PRESSURE PULSATION DAMPER
(See page SF±27)
3. INSTALL AIR INTAKE CHAMBER
(See page SF±49)
4. INSTALL ENGINE COVER
Install the engine cover with the 4 nuts.

SF0NF±03
B09504
B01582
B09505
SST
SF±26
± SFI (2JZ±GE)FUEL PRESSURE PULSATION DAMPER
1492 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
REMOVAL
1. REMOVE ENGINE COVER
Remove the 4 nuts and engine cover.
2. DISCONNECT CONNECTOR AND HOSES
(a) Disconnect the VSV connector for the EVAP.
(b) Disconnect the EVAP hose from the EVAP pipe.
(c) Disconnect the vacuum hose (from No.2 vacuum pipe)
from the air intake chamber.
3. REMOVE FUEL PRESSURE PULSATION DAMPER
(a) Remove the nut holding the No.2 vacuum pipe to the in-
take manifold.
(b) Remove the bolt holding the fuel inlet pipe to the intake
manifold.
(c) Using SST, remove the pulsation damper and 2 gaskets.
SST 09612±24014 (09617±24011)
CAUTION:

Put a shop towel under the delivery pipe.

Slowly loosen the pulsation damper.

SF0NG±04
B02000
New Gasket
(Large)
(Small)
New Gasket
B01582
B09504
± SFI (2JZ±GE)FUEL PRESSURE PULSATION DAMPER
SF±27
1493 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
INSTALLATION
1. INSTALL FUEL PRESSURE PULSATION DAMPER
(a) Install the fuel inlet pipe and pulsation damper with 2 new
gaskets.
HINT:
Different the gaskets are used for the upper (large side) and
lower (small side).
(b) Using SST, tighten the pulsation damper.
SST 09612 ± 24014 (09617 ± 24011)
Torque: 32.5 N´m (325 kgf´cm, 24 ft´lbf)
(c) Install the bolt holding the fuel inlet pipe to the intake man-
ifold.
Torque: 9.0 N´m (90 kgf´cm, 80 in.´lbf)
(d) Install the nut holding the No. 2 vacuum pipe to the intake
manifold.
Torque: 21 N´m (210 kgf´cm, 15 ft´lbf)
2. CONNECT CONNECTOR AND HOSES
(a) Connect the vacuum hose (from No.2 vacuum pipe) to the
air intake chamber.
(b) Connect the EVAP hose to the EVAP pipe.
(c) Connect the VSV connector for the EVAP.
3. INSTALL ENGINE COVER
Install the engine cover with the 4 nuts.

SF0NM±07
B09000
Intake Air Resonator
PCV Hose
PS Air Hose
Throttle Control
Motor ConnectorThrottle Body Bracket
Throttle Position Sensor Connector
Water Bypass HoseWater Bypass Hose Engine Wire ClampAccelerator Pedal Position
Sensor Connector
Accelerator Cable
21 (210, 15)
N´m (kgf´cm, ft´lbf) : Specified torqueThrottle Body
Engine Cover
B01947
CoverAccelerator Pedal Position Sensor
Washer Plate
Throttle Control Motor
Throttle Position Sensor Bracket
x 5
± SFI (2JZ±GE)THROTTLE BODY
SF±35
1501 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
COMPONENTS

SF0NN±05
B01615
B01616
Forward
Down±Side
Diagonal(2) (1)
SF±36
± SFI (2JZ±GE)THROTTLE BODY
1502 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
REMOVAL
1. DRAIN ENGINE COOLANT
2. REMOVE ENGINE COVER
Remove the 4 nuts and engine cover.
3. REMOVE INTAKE AIR RESONATOR
4. REMOVE THROTTLE BODY BRACKET AND
THROTTLE BODY
(a) Disconnect the accelerator cable.
(b) Disconnect the throttle position sensor connector.
(c) Disconnect the throttle control motor connector.
(d) Disconnect the accelerator pedal position sensor con-
nector.
(e) Disconnect the engine wire clamp from the clamp bracket
of throttle body.
(f) Remove the 2 bolts and nut holding the throttle body to
the intake air connector.
Torque: 21 N´m (210 kgf´cm, 15 ft´lbf)
(g) Remove the 4 nuts and throttle body bracket.
Torque: 21 N´m (210 kgf´cm, 15 ft´lbf)
(h) Slightly slide the throttle body away from the intake air
connector.
NOTICE:
When putting up the throttle body, do not hold the motor
part.
(i) Disconnect the 2 water bypass hoses from the throttle
body, and remove the throttle body.
HINT:

At the time of installation, please refer to the following
items.

Connect the water bypass hose with its discrimination
mark downward.

Install the with its craw direction for (1) forward and down±
side diagonal (engine side about 45°) for (2).

A02640
Ohmmeter
SF0NR±03
± SFI (2JZ±GE)CAMSHAFT TIMING OIL CONTROL VALVE
SF±41
1507 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
CAMSHAFT TIMING OIL CONTROL
VA LV E
ON±VEHICLE INSPECTION
1. INSPECT CAMSHAFT TIMING OIL CONTROL VALVE
RESISTANCE
(a) Disconnect the oil control valve connector.
(b) Using an ohmmeter, measure the resistance between the
terminals.
Resistance: 5.5 ± 12 W at 20°C (68°F)
If the resistance is not as specified, replace the valve.
(c) Reconnect the oil control valve connector.
2. INSPECT VVT±i OPERATION
(a) Allow the engine to warm up to normal operating tempera-
ture.
(b) Check that the engine stalls or becomes in rough±idling
state when the battery positive voltage is applied to the oil
control valve with the engine idling.
If operation is not as specified, check the oil control valve (see
page SF±43), VVT±i pulley, intake camshaft, wiring and ECM.