ES300 1992-1997

Timing Belt Front Cover

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Removal & Installation



  1. Disconnect the cable from the negative battery terminal.
  2.  
  3. Remove the power steering pump reservoir and position it out of the way. Remove the right fender apron seal and then remove the alternator and power steering belts.
  4.  
  5. Remove the coolant reservoir hose, the washer tank and then the coolant overflow tank.
  6.  
  7. Remove the right side engine mount stays.
  8.  
  9. Position a piece of wood on a floor jack and then slide the jack under the oil pan. Raise the jack slightly until the pressure is off the engine mounts.
  10.  
  11. Remove the engine control rod.
  12.  
  13. Remove the spark plugs.
  14.  
  15. Remove the right side engine mounting bracket.
  16.  
  17. Remove the 8 bolts and lift off the upper (No. 2) cover.

    Click image to see an enlarged view

    Fig. Remove the No. 2 timing belt cover

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  19. Paint matchmarks on the timing belt at all points where it meshes with the pulleys and the lower timing cover.
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  21. Set the No. 1 cylinder to TDC of the compression stroke and check that the timing marks on the camshaft timing pulleys are aligned with those on the No. 3 timing cover. If not, turn the engine 1 complete revolution (360 degrees) and check again.
  22.  
  23. Remove the timing belt tensioner and the dust boot.
  24.  
  25. Turn the right camshaft pulley clockwise slightly to release tension and then remove the timing belt from the pulleys.
  26.  
  27. Use a spanner wrench to hold the pulley, loosen the set bolt and then remove the camshaft timing pulleys along with the knock pin. Be sure to keep track of which is which.
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  29. Remove the No. 2 idler pulley.
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  31. Remove the crankshaft pulley.

    Click image to see an enlarged view

    Fig. Remove the crankshaft pulley bolt



    Click image to see an enlarged view

    Fig. Remove the crankshaft pulley

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  33. Remove the lower (No. 1) timing belt cover.

    Click image to see an enlarged view

    Fig. Remove the No. 1 timing belt cover

  34.  

To install:

  1. Install the lower (No. 1) timing cover and tighten the bolts.
  2.  
  3. Align the crankshaft pulley set key with the key groove on the pulley and slide the pulley on. Tighten the bolt to 181 ft. lbs. (245 Nm).
  4.  
  5. Install the No. 2 idler pulley and tighten the bolt to 29 ft. lbs. (39 Nm). Check that the pulley moves smoothly.
  6.  
  7. Install the left camshaft pulley with the flange side outward. Align the knock pin hole in the camshaft with the knock pin groove on the pulley and then install the pin. Tighten the bolt to 80 ft. lbs. (108 Nm).
  8.  
  9. Set the No. 1 cylinder to TDC again. Turn the right camshaft until the knock pin hole is aligned with the timing mark on the No. 3 belt cover. Turn the left pulley until the marks on the pulley are aligned with the mark on the No. 3 timing cover.
  10.  
  11. Check that the mark on the belt matches with the edge of the lower cover. If not, shift it on the crank pulley until it does. Turn the left pulley clockwise a bit and align the mark on the timing belt with the timing mark on the pulley. Slide the belt over the left pulley. Now move the pulley until the marks on it align with the 1 on the No. 3 cover. There should be tension on the belt between the crankshaft pulley and the left camshaft pulley.
  12.  
  13. Align the installation mark on the timing belt with the mark on the right side camshaft pulley. Hang the belt over the pulley with the flange facing inward. Align the timing marks on the right pulley with the 1 on the No. 3 cover and slide the pulley onto the end of the camshaft. Move the pulley until the camshaft knock pin hole is aligned with the groove in the pulley and then install the knock pin. Tighten the bolt to 55 ft. lbs. (75 Nm).
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  15. Position a plate washer between the timing belt tensioner and the block and then press in the pushrod until the holes are aligned between it and the housing. Slide a 1.27mm (3VZ-FE engine- 1.5mm) Allen wrench through the hole to keep the pushrod set. Install the dust boot and then install the tensioner. Tighten the bolts to 20 ft. lbs. (26 Nm). Don't forget to pull out the Allen wrench.
  16.  
  17. Turn the crankshaft clockwise 2 complete revolutions and check that all marks are still in alignment. If they aren't, remove the timing belt and start over again.
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  19. Install the remaining components. Install and adjust the drive belts.
  20.  
  21. Install the fender apron seal and the wheel.
  22.  
  23. Install the No. 2 stay and tighten the bolt to 55 ft. lbs. (75 Nm), the nut to 46 ft. lbs. (62 Nm). Install the No. 3 stay and tighten it to 54 ft. lbs. (73 Nm).
  24.  
  25. Install the coolant overflow tank and the washer tank.
  26.  
  27. Install the power steering reservoir tank and the cruise control actuator.
  28.  
  29. Connect the battery cable, start the vehicle and check for any leaks.
  30.  

 
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