2000 LEXUS GS400 Service Repair Manual

± 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

EM0DJ±03
A02768
N´m (kgf´cm, ft´lbf) : Specified torque
 Non±reusable part

Precoated partRH Engine Mounting Bracket and Insulator Assembly
No.2 Water Bypass Pipe with Hose
 Gasket
Water Pump

Engine Coolant Drain Plug
 O±Ring
21 (210, 15)
 O±Ring O±RingKnock Sensor 1
Knock Sensor 2
GeneratorFuel Inlet Pipe
Oil Pump
 Crankshaft Front Oil Seal
Oil Filter and
Bracket AssemblyNo.1 Oil Pipe
Union Bolt
55 (550, 41) Gasket
90 (900, 66)Union Bolt

Oil Pressure Switch
 Gasket21 (210, 15)
x 9
 O±Ring
x 6
x 6x 16
 Gasket
No.1 Oil Pan
Oil Pan Baffle Plate
Oil Strainer
LH Engine Mounting Bracket
and Insulator Assembly
 Gasket
x 16
No.2 Oil Pan
x 6
Drain Plug
EM±74
± ENGINE MECHANICAL (2JZ±GE)CYLINDER BLOCK
1428 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
CYLINDER BLOCK
COMPONENTS

A02806
Piston Ring (No.1 Compression)
Piston Ring
(Side Rail and Expander)Piston Ring (No.2 Compression)
Piston Pin
 Connecting Rod Bushing
Connecting Rod
Connecting Rod Bearing
Rear Oil Seal Retainer Piston
 Snap Ring
 Snap Ring
Connecting Rod Cap
 Crankshaft Rear Oil Seal
x 6
Cylinder Block
Crankshaft
Crankshaft Thrust Washer
Main Bearing CapMain Bearing
N´m (kgf´cm, ft´lbf) : Specified torque
 Non±reusable part
See page EM±91
1st 30 (300, 22)
2nd Turn 90°
See page EM±91
1st 45 (450, 33)
2nd Turn 90°
± ENGINE MECHANICAL (2JZ±GE)CYLINDER BLOCK
EM±75
1429 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)

EM0DK±03
P02447
EM±76
± ENGINE MECHANICAL (2JZ±GE)CYLINDER BLOCK
1430 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
DISASSEMBLY
1. INSTALL ENGINE TO ENGINE STAND FOR
DISASSEMBLY
2. REMOVE GENERATOR
Remove the bolt, nut, pipe bracket and generator.
3. REMOVE TIMING BELT AND PULLEYS
(See page EM±16)
4. REMOVE NO.2 WATER BYPASS PIPE WITH HOSE
Remove the bolt, 2 nuts, No.2 water bypass pipe and gasket.
5. REMOVE WATER PUMP
Remove the 6 bolts, water pump and O±ring.
6. REMOVE CYLINDER HEAD (See page EM±33)
7. REMOVE OIL PRESSURE SWITCH AND KNOCK
SENSORS
Using SST, remove the switch and sensors.
SST 09816±30010
8. REMOVE OIL FILTER AND BRACKET ASSEMBLY
(a) Remove the union bolt and oil filter bracket.
(b) Remove the gasket from the union bolt.
(c) Remove the O±ring from the oil filter bracket.
9. REMOVE NO.1 OIL PIPE
Remove the union bolt, No.1 oil pipe and 2 gaskets.
10. REMOVE FUEL INLET PIPE
Remove the 2 bolts and fuel inlet pipe.
11. REMOVE LH ENGINE MOUNTING BRACKET AND
INSULATOR ASSEMBLY
Remove the 4 bolts and mounting bracket.
12. REMOVE RH ENGINE MOUNTING BRACKET AND
INSULATOR ASSEMBLY
Remove the 4 bolts and mounting bracket.
13. REMOVE OIL PUMP (See page LU±6)
14. REMOVE REAR OIL SEAL RETAINER
(a) Remove the 6 bolts of the retainer.
(b) Remove the oil seal retainer by prying the area between
the oil seal retainer and main bearing cap with a screw-
driver.

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)

P04470
Z02391
Mark
1, 2, 3 , 4 or 5
Mark
1, 2 or 3
Mark
0, 1 or 2
No.1
No.2
No.3No.4No.5No.6
Number mark
12
22 33
1
Connecting rod cap
Crankshaft
Use bearing
EXAMPLE: Connecting rod cap º3º + Crankshaft º1º
= Total number 4 (Use bearing º4º)12 3
0120120
34 4 5 EM±78
± ENGINE MECHANICAL (2JZ±GE)CYLINDER BLOCK
1432 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
(i) Measure the Plastigage at its widest point.
Standard oil clearance:
STD0.023 ± 0.041 mm (0.0009 ± 0.0016 in.)
U/S 0.250.028 ± 0.066 mm (0.0011 ± 0.0026 in.)
Maximum oil clearance:
STD0.07 mm (0.0027 in.)
U/S 0.250.08 mm (0.0031 in.)
If the oil clearance is greater than maximum, replace the bear-
ings. If necessary, grind or replace the crankshaft.
HINT:
If using a standard bearing, replace with one having the same
number. If the number of the bearing cannot be determined, se-
lect the correct bearing by adding together the numbers im-
printed on the connecting rod cap and crankshaft, then select-
ing the bearing with the same number as the total. There are 5
sizes of standard bearings, marked º1º, º2º, º3º, º4º and º5º ac-
cordingly.
Reference
Connecting rod big end inside diameter:
Mark º1º55.025 ± 55.031 mm (2.1663 ± 2.1666 in.)
Mark º2º55.031 ± 55.037 mm (2.1666 ± 2.1668 in.)
Mark º3º55.037 ± 55.043 mm (2.1668 ± 2.1670 in.)
Crankshaft crank pin diameter:
Mark º0º51.994 ± 52.000 mm (2.0470 ± 2.0472 in.)
Mark º1º51.988 ± 51.994 mm (2.0468 ± 2.0470 in.)
Mark º2º51.982 ± 51.988 mm (2.0465 ± 2.0468 in.)
Standard sized bearing center wall thickness:
Mark º1º1.498 ± 1.501 mm (0.0590 ± 0.0591 in.)
Mark º2º1.501 ± 1.504 mm (0.0591 ± 0.0592 in.)
Mark º3º1.504 ± 1.507 mm (0.0592 ± 0.0593 in.)
Mark º4º1.507 ± 1.510 mm (0.0593 ± 0.0594 in.)
Mark º5º1.510 ± 1.513 mm (0.0594 ± 0.0596 in.)
(j) Completely remove the Plastigage.

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.

P04792
Plastigage
P04468
A02784
Mark
0, 1, 2, 3, 4,
5, 6 or 7
1, 2, 3, 4 or 5Mark
0, 1, 2, 3, 4,
5, 6 or 7 No.1
No.5No.6
No.2
No.3
No.4No.7
No.1
No.2
Mark No.3
No.4No.5No.6No.7 (A)
(B)
Cylinder block (A)
Crankshaft (B) =+Total number º º : Number mark
Use bearing0±2 3±5 6±8 9±11 12±14
º2º º3º º1º º5ºº4º
EXAMPLE: Cylinder block º3º (A)
+ Crankshaft º4º (B)
= Total number 7 (Use bearing º3º) EM±80
± ENGINE MECHANICAL (2JZ±GE)CYLINDER BLOCK
1434 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
(g) Lay a strip of Plastigage across each journal.
(h) Install the main bearing caps. (See page EM±91)
Torque:
1st 45 N´m (450 kgf´cm, 33 ft´lbf)
2nd Turn extra 90°
NOTICE:
Do not turn the crankshaft.
(i) Remove the main bearing caps.
(See procedures (a) and (b) above)
(j) Measure the Plastigage at its widest point.
Standard clearance:
STD0.026 ± 0.040 mm (0.0010 ± 0.0016 in.)
U/S 0.250.025 ± 0.061 mm (0.0010 ± 0.0024 in.)
Maximum clearance:
STD0.06 mm (0.0024 in.)
U/S 0.250.08 mm (0.0031 in.)
If the oil clearance is greater than maximum, replace the bear-
ings. If necessary, grind or replace the crankshaft.
HINT:
If using a standard bearing, replace with one having the same
number. If the number of the bearing cannot be determined, se-
lect the correct bearing by adding together the numbers im-
printed on the cylinder block and crankshaft, then refer to the
table below for the appropriate bearing number. There are 5
sizes of standard bearings, marked º1º, º2º, º3º, º4º and º5º ac-
cordingly.