check engine LEXUS GS400 2000 Service Manual PDF

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.

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.

A02665
EX
IN
35 24
35 24
66
66
P02094
Upward
Cam Lobe
Notch
P12860
EX Side
IN SideSST (B)
P12294
SST (A)
P11926
SST (A) SST (B)
7
± ENGINE MECHANICAL (2JZ±GE)VALVE CLEARANCE
EM±7
1361 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
(c) Check only the valves indicated as shown. Measure the
valve clearance. (See procedure in step (a))
12. ADJUST VALVE CLEARANCE
(a) Remove the adjusting shim.

Turn the camshaft so that the cam lobe for the valve
to be adjusted faces up.

Turn the valve lifter with a screwdriver so that the
notches are perpendicular to the camshaft.

Insert SST (B) gently from the inside as shown in the
illustration.

Using SST (A), hold the camshaft as shown in the
illustration.
SST 09248±55040 (09248±05410)

Using SST (A), press down the valve lifter and place
SST (B) between the camshaft and valve lifter. Re-
move SST (A).
SST 09248±55040 (09248±05410, 09248±05420)
HINT:

Apply SST (B) at slight angle on the side marked with º7º
or º9º, at the position shown in the illustration.

± 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

A02715
SST
A02702
± ENGINE MECHANICAL (2JZ±GE)CYLINDER HEAD
EM±51
1405 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
(f) Using SST, compress the valve spring and place the 2
keepers around the valve stem.
SST 09202±70020 (09202±00010)
(g) Using a plastic±faced hammer, lightly tap the valve stem
tip to assure proper fit.
3. INSTALL VALVE LIFTERS AND SHIMS
(a) Install the valve lifter and shim.
(b) Check that the valve lifter rotates smoothly by hand.
4. INSTALL ECT SENSOR
Torque: 19.6 N´m (200 kgf´cm, 14 ft´lbf)
5. INSTALL CAMSHAFT POSITION SENSOR
6. INSTALL ENGINE HANGER
Torque: 40 N´m (400 kgf´cm, 30 ft´lbf)
7. INSTALL WATER OUTLET WITH WATER BYPASS
HOSE
Install a new gasket and the water outlet with the bolt and 2
nuts.
Torque: 28 N´m (280 kgf´cm, 21 ft´lbf)

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.

S02644SST
B02434
B02435
120°120°
B02436
120°120°
A02727
Front Mark
EM±54
± ENGINE MECHANICAL (2JZ±GE)CYLINDER HEAD
1408 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
(n) Using SST, push the 2 oil seals in as far as they can go.
SST 09316±60011 (09316±00011, 09316±00051)
(o) Rotate the camshaft with a wrench at the hexagon posi-
tion, bring the forward straight pin up.
(p) Loosen the 12 bearing cap bolts as shown, until they can
be turned by hand; retighten in several passes.
Torque: 20 N´m (200 kgf´cm, 15 ft´lbf)
(q) Turn the camshaft 1/3 of a revolution.
(r) Loosen the 8 bearing cap bolts as shown, until they can
be turned by hand; retighten in several passes.
Torque: 20 N´m (200 kgf´cm, 15 ft´lbf)
(s) Turn the camshaft a further 1/3 of a revolution.
(t) Loosen the 8 bearing cap bolts as shown, until they can
be turned by hand; retighten in several passes.
Torque: 20 N´m (200 kgf´cm, 15 ft´lbf)
4. CHECK AND ADJUST VALVE CLEARANCE
(See page EM±5)
5. INSTALL NO.4 TIMING BELT COVER
Install the timing belt cover with 4 bolts.
Torque: 8.0 N´m (80 kgf´cm, 71 in.´lbf)
6. INSTALL CAMSHAFT TIMING PULLEYS
(a) Install the exhaust camshaft timing pulley.
(1) Align the camshaft knock pin with the groove in the
pulley, and slide on the pulley.
(2) Slide the timing pulley on the camshaft, facing the
front mark forward.
(3) Hold the hexagon portion of the camshaft with a
wrench, and tighten the timing pulley bolt.
Torque: 81 N´m (810 kgf´cm, 60 ft´lbf)

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