2000 LEXUS GS400 check engine

A02765
EVAP Hose
A02751
A02753
EVAP
Hose Clamp
MAF Meter
Connector
EM±72
± ENGINE MECHANICAL (2JZ±GE)ENGINE UNIT
1426 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
(g) Connect the heated oxygen sensor (bank 1 sensor 1)
connector.
(h) Connect the heated oxygen sensor (bank 1 sensor 2)
connector.
(i) Connect the EVAP hose to the pipe (from charcoal canis-
ter).
(j) Connect the heater hose to the heater pipe.
(k) Connect the heater hose to the water bypass pipe.
(l) Connect the ground strap to the dash panel.
(m) Connect the fuel inlet hose to the fuel pipe support.
Torque: 29 N´m (300 kgf´cm, 22 ft´lbf)
(n) Connect the starter wire to the terminal and manifold stay.
(o) Connect the ground wire to the floor.
16. INSTALL FRONT SUSPENSION MEMBER BRACE
Install the brace with the 6 bolts.
Torque: 58 N´m (590 kgf´cm, 43 ft´lbf)
17. INSTALL DRIVE BELT (See page CH±1)
18. INSTALL RADIATOR ASSEMBLY (See page CO±23)
19. CONNECT ACCELERATOR CABLE TO ENGINE
20. INSTALL AIR CLEANER, MAF METER AND INTAKE
AIR CONNECTOR PIPE ASSEMBLY
(a) Connect the intake air resonator to the throttle body.
(b) Install the air cleaner case with the 3 bolts.
(c) Tighten the hose clamp bolt holding the intake air resona-
tor to the throttle body.
(d) Connect the MAF meter connector.
(e) Connect the engine wire clamp to the air cleaner case.
(f) Connect the EVAP hose to the air cleaner case.
(g) Connect the PS air hose to the No.4 timing belt cover.
(h) Connect the PCV hose to the No.2 cylinder head cover.
21. INSTALL AIR CLEANER INLET
22. INSTALL ENGINE COVER
Install the engine cover with the 4 nuts.
23. FILL WITH ENGINE COOLANT
24. FILL WITH ENGINE OIL
25. START ENGINE AND CHECK FOR LEAKS
26. INSTALL ENGINE UNDER COVER

± ENGINE MECHANICAL (2JZ±GE)ENGINE UNIT
EM±73
1427 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
27. INSTALL HOOD
NOTICE:
Be careful not to damage the body or glass with the hood
end.
28. PERFORM ROAD TEST
Check for abnormal noise, shock, slippage, correct shift points
and smooth operation.
29. RECHECK ENGINE COOLANT AND OIL LEVELS

P04467
P02436
P04469
P04599
Plastigage
P02426
± ENGINE MECHANICAL (2JZ±GE)CYLINDER BLOCK
EM±77
1431 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
15. CHECK CONNECTING ROD THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while mov-
ing the connecting rods back and forth.
Standard thrust clearance:
0.250 ± 0.402 mm (0.0098 ± 0.0158 in.)
Maximum thrust clearance:
0.50 mm (0.0197 in.)
If the thrust clearance is greater than maximum, replace the
connecting rod assembly(s). If necessary, replace the crank-
shaft.
Connecting rod thickness:
25.898 ± 25.950 mm (1.0196 ± 1.0217 in.)
16. REMOVE CONNECTING ROD CAPS AND CHECK
OIL CLEARANCE
(a) Check the matchmarks on the connecting rod and cap to
ensure correct reassembly.
(b) Remove the connecting rod cap bolts.
(c) Using the 2 removed connecting rod bolts, remove the
connecting rod cap and lower bearing by wiggling the
connecting rod cap right and left.
HINT:
Keep the lower bearing inserted with the connecting rod cap.
(d) Clean the crank pin and bearings.
(e) Check the crank pin and bearing for pitting and scratches.
If the crank pin or bearing is damaged, replace the bearings. If
necessary, replace the crankshaft.
(f) Lay a strip of Plastigage across the crank pin.
(g) Install the connecting rod cap with the 2 bolts.
(See page EM±91)
Torque:
1st 30 N´m (300 kgf´cm, 22 ft´lbf)
2nd Turn extra 90°
NOTICE:
Do not turn the crankshaft.
(h) Remove the 2 bolts, connecting rod cap and lower bear-
ing. (See procedure (b) and (c) above)

A02684
Z07401
412
8141062
371113951
P04472
P04471
± ENGINE MECHANICAL (2JZ±GE)CYLINDER BLOCK
EM±79
1433 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
17. REMOVE PISTON AND CONNECTING ROD
ASSEMBLIES
(a) Using a ridge reamer, remove all the carbon from the top
of the cylinder.
(b) Push the piston, connecting rod assembly and upper
bearing through the top of the cylinder block.

Keep the bearings, connecting rod and cap togeth-
er.

Arrange the piston and connecting rod assemblies
in correct order.
18. CHECK CRANKSHAFT THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while prying
the crankshaft back and forth with a screwdriver.
Standard thrust clearance:
0.020 ± 0.220 mm (0.0008 ± 0.0087 in.)
Maximum thrust clearance:
0.30 mm (0.0118 in.)
If the thrust clearance is greater than maximum, replace the
thrust washers as a set.
Thrust washer thickness:
1.940 ± 1.990 mm (0.0764 ± 0.0783 in.)
19. REMOVE MAIN BEARING CAPS AND CHECK OIL
CLEARANCE
(a) Uniformly loosen and remove the 14 main bearing cap
bolts, in several passes, in the sequence shown.
(b) Using the removed main bearing cap bolts, pry the main
bearing cap back and forth, and remove the main bearing
caps, lower bearings and lower thrust washers (No.4
main bearing cap only).
HINT:

Keep the lower bearing and main bearing cap together.

Arrange the main bearing caps and lower thrust washers
in correct order.
(c) Lift out the crankshaft.
HINT:
Keep the upper bearing and upper thrust washers together with
the cylinder block.
(d) Clean each main journal and bearing.
(e) Check each main journal and bearing for pitting and
scratches.
If the journal or bearing is damaged, replace the bearings. If
necessary, grind or replace the crankshaft.
(f) Place the crankshaft on the cylinder block.

P02292
A02673
A02679
A02674
P02278
EM±82
± ENGINE MECHANICAL (2JZ±GE)CYLINDER BLOCK
1436 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
20. REMOVE CRANKSHAFT
(a) Lift out the crankshaft
(b) Remove the upper bearings and upper thrust washers
from the cylinder block.
HINT:
Arrange the main bearing caps, bearings and thrust washers in
the correct order.
21. CHECK FIT BETWEEN PISTON AND PISTON PIN
Try to move the piston back and forth on the piston pin.
If any movement is felt, replace the piston and pin as a set.
22. REMOVE PISTON RINGS
(a) Using a piston ring expander, remove the 2 compression
rings.
(b) Remove the 2 side rails and oil ring expander by hand.
HINT:
Arrange the piston rings in correct order only.
23. DISCONNECT CONNECTING ROD FROM PISTON
(a) Using a small screwdriver, remove the 2 snap rings.
(b) Gradually heat the piston to about 80°C (176°F).
(c) Using a plastic±faced hammer and brass bar, lightly tap
out the piston pin and remove the connecting rod.
HINT:

The piston and pin are a matched set.

Arrange the pistons, pins, rings, connecting rods and
bearings in the correct order.

EM0DL±03
A02685
Z02380
P02286
EM0365
1 Thrust Direction
2 Axial Direction1
2
A
B
C10 mm (0.39 in.)
Middle
10 mm (0.39 in.)
A02684
± ENGINE MECHANICAL (2JZ±GE)CYLINDER BLOCK
EM±83
1437 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
INSPECTION
1. CLEAN CYLINDER BLOCK
(a) Remove gasket material
Using a gasket scraper, remove all the gasket material
from the cylinder block surface.
(b) Clean cylinder block
Using a soft brush and solvent, thoroughly clean the cylin-
der block.
2. INSPECT CYLINDER BLOCK SURFACE FOR
FLATNESS
Using precision straight edge and feeler gauge,
measure the top surfaces of the cylinder block for warpage.
Maximum warpage: 0.07 mm (0.0028 in.)
If warpage is greater than maximum, replace the cylinder block.
3. INSPECT CYLINDER FOR VERTICAL SCRATCHES
Visually check the cylinder for vertical scratches.
If deep scratches are present, replace the cylinder block.
4. INSPECT CYLINDER BORE DIAMETER
Using a cylinder gauge, measure the cylinder bore diameter at
positions A, B and C in the thrust and axial directions.
Standard diameter:
86.000 ± 86.013 mm (3.3858 ± 3.3863 in.)
Maximum diameter:
86.02 mm (3.3866 in.)
If the diameter is greater than maximum, replace the cylinder
block.
5. REMOVE CYLINDER RIDGE
If the wear is less than 0.2 mm (0.008 in.), using a ridge reamer,
grind the top of the cylinder.

Z02381
Z02382
P02275
EM0227
EM±86
± ENGINE MECHANICAL (2JZ±GE)CYLINDER BLOCK
1440 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
12. INSPECT CONNECTING ROD ALIGNMENT
Using a feeler gauge and rod aligner, check the connecting rod
alignment.

Check for out±of±alignment
Maximum out±of±alignment:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If out±of±alignment is greater than maximum, replace the con-
necting rod assembly.

Check for twist
Maximum twist:
0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
If twist is greater than maximum, replace the connecting rod as-
sembly.
13. INSPECT PISTON PIN OIL CLEARANCE
(a) Using a caliper gauge, measure the inside diameter of the
connecting rod bushing.
Bushing inside diameter:
22.005 ± 22.014 mm (0.8663 ± 0.8667 in.)
(b) Using a micrometer, measure the piston pin diameter.
Piston pin diameter:
21.997 ± 22.006 mm (0.8660 ± 0.8664 in.)
(c) Subtract the piston pin diameter measurement from the
bushing in side diameter measurement.
Standard oil clearance:
0.005 ± 0.011 mm (0.0002 ± 0.0004 in.)
Maximum oil clearance:
0.05 mm (0.0020 in.)
If the oil clearance is greater than maximum, replace the bush-
ing. If necessary, replace the piston and piston pin as a set.

P02459
About
20 mmCompressed
P02153
Z02383
± ENGINE MECHANICAL (2JZ±GE)CYLINDER BLOCK
EM±87
1441 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
14. INSPECT CONNECTING ROD BOLTS
Using vernier calipers, measure the minimum diameter of the
compressed bolt at the measuring point.
Standard diameter: 8.1 ± 8.3 mm (0.319 ± 0.327 in.)
Minimum diameter: 8.0 mm (0.315 in.)
If the diameter is less than minimum, replace the connecting rod
bolt.
15. INSPECT CRANKSHAFT FOR RUNOUT
(a) Place the crankshaft on V±blocks.
(b) Using a dial indicator, measure the circle runout at the
center journal.
Maximum circle runout: 0.06 mm (0.0024 in.)
If the circle runout is greater than maximum, replace the crank-
shaft.
16. INSPECT MAIN JOURNALS AND CRANK PINS
(a) Using a micrometer, measure the diameter of each main
journal and crank pin.
Main journal diameter:
STD61.984 ± 62.000 mm (2.4403 ± 2.4409 in.)
U/S 0.2561.745 ± 61.755 mm (2.4309 ± 2.4313 in.)
Crank pin diameter:
STD51.982 ± 52.000 mm (2.0465 ± 2.0472 in.)
U/S 0.2551.745 ± 51.755 mm (2.0372 ± 2.0376 in.)
If the diameter is not as specified, check the oil clearance.
(See page EM±76)
(b) Check each main journal and crank pin for taper and out±
of±round as shown.
Maximum taper and out±of round:
0.02 mm (0.0008 in.)
If the taper or out±of±round is greater than maximum, grind or
replace the crankshaft.
17. IF NECESSARY, GRIND AND HONE MAIN
JOURNALS AND/OR CRANK PINS

Grind and hone the main journals and/or crank pins to the
finished undersized diameter (See procedure step 16).

Install new main journal and/or crank pin undersized
bearings.