REMOVAL & INSTALLATION

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Juniper Stanley
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1 REMOVAL & INSTALLATION CAUTION: This application is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur. TIMING BELT Removal 1. Raise and support vehicle. Remove engine undercover. Drain cooling system. 2. On IS 300 M/T, remove drive belt tensioner absorber. On GS 300 and all IS 300 models, remove air cleaner inlet, air cleaner, and MAF assembly. Remove radiator and electric cooling fan assembly. On models, rotate serpentine drive belt tensioner COUNTERCLOCKWISE and remove belt. Tensioner bolt has LEFT-HAND threads. On 2000 and later models, rotate tensioner CLOCKWISE to remove serpentine belt. 3. On SC 300, remove battery and battery tray. Drain coolant. Remove lower fan shroud. Remove radiator. Loosen 4 nuts holding fan clutch to water pump. Rotate serpentine drive belt tensioner bolt CLOCKWISE, and remove drive belt. Remove cooling fan, fan clutch, and water pump pulley. 4. On all models, remove power steering pump front bracket. Remove pump with hoses attached, and hang out of way. Remove No. 2 and No. 3 timing belt covers and gaskets. See Fig. 1. Being careful not to drop bolts inside timing belt cover, remove serpentine drive belt tensioner. 5. Using Handle ( ) and Pulley Holder ( ) or equivalent to hold crankshaft pulley, loosen crankshaft pulley bolt. Rotate crankshaft CLOCKWISE so cylinder No. 1 (front cylinder) is at TDC on compression stroke. Ensure timing mark on crankshaft pulley aligns with "0" mark on No. 1 timing belt cover. See Fig. 2 and Fig Timing marks on camshaft timing pulleys must align with timing marks on No. 4 timing belt cover. See Fig. 2. If not, rotate crankshaft CLOCKWISE one complete revolution (360 degrees). CAUTION: Crankshaft must be correctly positioned by aligning sub-timing mark (60 degree mark BTDC) with "0" mark on timing belt cover to prevent valves from contacting pistons. 7. Rotate crankshaft pulley 60 degrees COUNTERCLOCKWISE. Align sub-timing mark with "0" mark on timing belt cover. See Fig. 3, STEP 1. Ensure the dot marks of camshaft timing pulleys are aligned with the timing marks of No. 4 timing belt cover. See Fig. 3, STEP 2. CAUTION: If reusing timing belt, place arrow on timing belt to indicate direction of rotation. Place reference mark on timing belt and each camshaft timing pulley for reassembly reference. 8. DO NOT allow the crankshaft pulley to rotate. Remove crankshaft pulley bolt. 9. Alternately loosen timing belt tensioner bolts. Remove bolts, timing belt tensioner, and dust boot. See Fig. 1. Remove timing belt from camshaft sprockets. 10. Remove crankshaft pulley using gear puller. Remove No. 1 timing belt cover and gaskets. Note direction Friday, October 24, :36:04 9:36:09 AM Page Mitchell Repair Information Company, LLC.

2 of timing belt guide installation for reassembly reference (flat side toward timing belt). See Fig. 1. Remove timing belt guide. If reusing timing belt, place mating reference marks on timing belt and crankshaft sprocket. Remove timing belt. Fig. 1: Exploded View Of Timing Belt & Components Friday, October 24, :36:05 AM Page Mitchell Repair Information Company, LLC.

3 Fig. 2: Aligning Camshaft Timing Marks Friday, October 24, :36:05 AM Page Mitchell Repair Information Company, LLC.

4 Fig. 3: Aligning Sub-Timing Marks Inspection Friday, October 24, :36:05 AM Page Mitchell Repair Information Company, LLC.

5 1. Inspect timing belt for damaged teeth, cracking or oil contamination. Replace timing belt if damaged or contaminated. Check idler pulley and drive belt tensioner pulley for smooth rotation. Replace idler pulley or drive belt tensioner if defective. Inspect timing belt tensioner for signs of oil leakage. Replace timing belt tensioner if oil leakage exists. NOTE: Timing belt tensioner may have a small amount of oil on rod seal under normal conditions. If excessive amount of oil exists, replace timing belt tensioner. 2. Hold timing belt tensioner body, and press push rod against solid surface. Replace timing belt tensioner if push rod moves. Measure timing belt tensioner push rod protrusion from end of rod to edge of housing. See Fig. 4. Replace timing belt tensioner if distance is not " ( mm). 3. On IS 300 M/T, compress and extend drive belt tensioner absorber rod. If there is abnormal resistance or operation, replace as necessary. Fig. 4: Measuring Timing Belt Tensioner Rod Protrusion Installation 1. Install idler pulley and plate washer (if removed). Apply Loctite 242 or equivalent on threads of idler pulley pivot bolt. Install and tighten bolt to specification. See TORQUE SPECIFICATIONS. Ensure idler pulley is clean and rotates smoothly, and idler pulley bracket moves freely. Friday, October 24, :36:05 AM Page Mitchell Repair Information Company, LLC.

6 NOTE: The engine should be cold before adjusting timing marks. CAUTION: If reusing timing belt, ensure reference marks on timing belt and crankshaft timing pulley align, and timing belt is installed in original direction of rotation. 2. Using crankshaft pulley bolt, rotate crankshaft and align timing mark on crankshaft timing pulley with timing mark on oil pump body. See Fig. 3, STEP 3. Clean oil or water off of crankshaft timing pulley, and install timing belt on crankshaft timing pulley and around idler pulley. 3. Install timing belt guide with cupped side away from crankshaft timing pulley and flat side against timing belt. Install gasket and No. 1 timing belt cover. Align crankshaft pulley key groove with crankshaft key. Install crankshaft pulley. 4. Ensure sub-timing mark (60 degrees BTDC) of crankshaft pulley is aligned with "0" timing mark of No. 1 timing belt cover. See Fig. 3, STEP 4. Temporarily install crankshaft pulley bolt. CAUTION: If reusing timing belt, ensure reference marks on timing belt and camshaft timing pulleys align and timing belt is installed in original direction of rotation. 5. If necessary, use spanner wrench to rotate camshaft timing pulleys so timing marks on camshaft timing pulleys align with timing marks on No. 4 timing belt cover. See Fig. 2. Install timing belt on camshaft timing pulleys. Ensure tension exists on timing belt between camshaft timing pulleys. 6. Using press, SLOWLY apply pressure of lbs. ( N) on push rod of timing belt tensioner until rod is retracted and holes in rod and housing are aligned. See Fig Install 1.5 mm hexagon wrench through holes in housing and rod to hold rod in retracted position. See Fig. 5. Release press. Install dust boot on timing belt tensioner. Install timing belt tensioner with 2 bolts. Alternately tighten timing belt tensioner bolts to specification. See TORQUE SPECIFICATIONS. CAUTION: Always rotate crankshaft CLOCKWISE. DO NOT rotate crankshaft COUNTERCLOCKWISE. 8. Remove hexagon wrench from timing belt tensioner. Rotate crankshaft CLOCKWISE 2 full revolutions from TDC to TDC. 9. Ensure timing marks on camshaft timing pulleys align with timing marks on timing belt cover, and timing mark on crankshaft pulley aligns with "0" mark on timing belt cover. If timing marks are not aligned, remove timing belt and reinstall. 10. Tighten crankshaft pulley bolt to specification. Install drive belt tensioner. Install No. 2 and No. 3 timing belt covers. To install remaining components, reverse removal procedure. Use care when installing drive belt tensioner bolts to avoid dropping bolts into timing belt cover. 11. Tighten fasteners to specification. See TORQUE SPECIFICATIONS. Fill and bleed air from cooling system. See COOLING SYSTEM BLEEDING. Friday, October 24, :36:05 AM Page Mitchell Repair Information Company, LLC.

7 Fig. 5: Retracting Timing Belt Tensioner Rod COOLING SYSTEM BLEEDING 1. Fill cooling system. Install radiator cap. Move heater control to warmest position. Start engine. Maintain engine speed at RPM until engine is at normal operating temperature. 2. Shut engine off. Allow engine to cool. Recheck coolant level. Fill coolant level to FULL line on coolant reservoir if necessary. TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Timing Pulley Bolt 60 (81) Crankshaft Pulley Bolt 243 (330) Drive Belt Tensioner Absorber Nut (IS 300 M/T) 14 (20) Drive Belt Tensioner Bolt 15 (21) Fan Clutch-To-Water Pump Nut (SC 300) 12 (16) Idler Pulley Bolt (1) 26 (35) Power Steering Pump Front Bracket Bolts Friday, October 24, :36:05 AM Page Mitchell Repair Information Company, LLC.

8 Bottom Bolt 38 (52) Top Bolts (2) 43 (58) Timing Belt Tensioner Bolt 20 (27) Water Pump Bolt 15 (21) INCH Lbs. (N.m) Fan-To-Fan Clutch Nuts (SC 300) 65 (7.5) Timing Belt Cover Bolts 71 (8) Timing Belt Plate Bolt 71 (8) (1) Apply Loctite 242 or equivalent to bolt threads. Friday, October 24, :36:05 AM Page Mitchell Repair Information Company, LLC.

EG-34 ENGINE MECHANICAL TIMING BELT COMPONENTS FOR REMOVAL AND INSTALLATION

EG-34 ENGINE MECHANICAL TIMING BELT COMPONENTS FOR REMOVAL AND INSTALLATION EG34 TIMING BELT COMPONENTS FOR REMOVAL AND INSTALLATION EG35 TIMING BELT REMOVAL (See Components for Removal and Installation) 1. DISCONNECT NEGATIVE TERMINAL CABLE FROM BATTERY CAUTION: Work must be