Lexus GS300/400 (2000 year). Manual - part 149

Crankshaft
number mark

Cylinder block number mark

EXAMPLE:  Cylinder block ”3” Crankshaft ”4”

= Use bearing ”3”

0

1

2

3

4
5

6

7

0

1

2

3

4

5

6

7

1

1

1

2

2

2

3

3

1

1

2

2

2

3

3

3

1

2

2

2

3

3

3

4

2

2

2

3

3

3

4

4

2

2

3

3

3

4

4

4

2

3

3

4

4

3

4

4

3

3

4

4

3

5

5

5

3

4

4

3

5

5

5

5

–

ENGINE MECHANICAL (2JZ–GE)

CYLINDER BLOCK

EM–81

1435

Standard sized bearing selection chart:

Reference
Cylinder block main journal bore diameter (A):

Mark ”0”

66.020 – 66.022 mm (2.59922 – 2.59929 in.)

Mark ”1”

66.022 – 66.024 mm (2.59929 – 2.59936 in.)

Mark ”2”

66.024 – 66.026 mm (2.59936 – 2.59944 in.)

Mark ”3”

66.026 – 66.028 mm (2.59944 – 2.59952 in.)

Mark ”4”

66.028 – 66.030 mm (2.59952 – 2.59960 in.)

Mark ”5”

66.030 – 66.032 mm (2.59960 – 2.59968 in.)

Mark ”6”

66.032 – 66.034 mm (2.59968 – 2.59976 in.)

Mark ”7”

66.034 – 66.036 mm (2.59976 – 2.59984 in.)

Crankshaft main journal diameter (B):

Mark ”0”

61.998 – 62.000 mm (2.44086 – 2.44094 in.)

Mark ”1”

61.996 – 61.998 mm (2.44078 – 2.44086 in.)

Mark ”2”

61.994 – 61.996 mm (2.44070 – 2.44078 in.)

Mark ”3”

61.992 – 61.994 mm (2.44063 – 2.44070 in.)

Mark ”4”

61.990 – 61.992 mm (2.44055 – 2.44063 in.)

Mark ”5”

61.988 – 61.990 mm (2.44047 – 2.44055 in.)

Mark ”6”

61.986 – 61.988 mm (2.44039 – 2.44047 in.)

Mark ”7”

61.984 – 61.986 mm (2.44031 – 2.44039 in.)

Standard bearing center wall thickness:

Mark ”1”

1.994 – 1.997 mm (0.0785 – 0.0786 in.)

Mark ”2”

1.997 – 2.000 mm (0.0786 – 0.0787 in.)

Mark ”3”

2.000 – 2.003 mm (0.0787 – 0.0789 in.)

Mark ”4”

2.003 – 2.006 mm (0.0789 – 0.0790 in.)

Mark ”5”

2.006 – 2.009 mm (0.0790 – 0.0791 in.)

(k)

Completely remove the Plastigage.

P02292

A02673

A02679

A02674

P02278

EM–82

–

ENGINE MECHANICAL (2JZ–GE)

CYLINDER BLOCK

1436

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 Direction

1

2

A

B

C

10 mm (0.39 in.)

Middle

10 mm (0.39 in.)

A02684

–

ENGINE MECHANICAL (2JZ–GE)

CYLINDER BLOCK

EM–83

1437

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.

A02827

About
50 mm

Compressed
Thread

A02675

A02676

A02677

34 mm

EM–84

–

ENGINE MECHANICAL (2JZ–GE)

CYLINDER BLOCK

1438

6.

INSPECT MAIN BEARING CAP BOLTS

Using vernier calipers, measure the minimum diameter of the
compressed thread at the measuring point.

Standard diameter: 
9.96 – 9.97 mm (0.3921 – 0.3925 in.)
Minimum diameter:
9.7 mm (0.382 in.)

If the diameter is less than minimum, replace the bolt.

7.

CLEAN PISTON

(a)

Using a gasket scraper, remove the carbon from the pis-
ton top.

(b)

Using a groove cleaning tool or broken ring, clean the pis-
ton ring grooves.

(c)

Using solvent and a brush, thoroughly clean the piston.

NOTICE:
Do not use a wire brush.

8.

INSPECT PISTON OIL CLEARANCE

(a)

Using a micrometer, measure the piston diameter at right
angles to the piston pin center line, 34 mm (1.34 in.) from
the piston head.
Piston diameter:
85.945 – 85.965 mm (3.3837 – 3.3844 in.)

(b)

Measure the cylinder bore diameter in the thrust direc-
tions. (See step 4)

(c)

Subtract the piston diameter measurement from the cylin-
der bore diameter measurement.
Standard oil clearance:
0.035 – 0.068 mm (0.0014 – 0.0027 in.)
Maximum oil clearance:
0.10 mm (0.0039 in.)

If the oil clearance is greater than maximum, replace all the 6
pistons. If necessary, replace the cylinder block.