How long for TDI timing belt change

[scotyp]

Hi All,

Does any one know how long it takes for a first timer to change a 300 tdi timing belt, I plan on removing the radiator etc, but I believe you also need some special tools or can they be subsituted with other tools,

Thanks in advance

Scotty P

[big guy]

Not sure how long a home mechanic would take, I guess it would depend on skill and tools etc but my mech charged me 3 hrs and that included changing all radiater hoses as well.

Good luck.

[Jojo]

I haven't done it myself (on the Disco anyway), but a friend of mine, who is a car mechanic, did it in about four hours. You will need a tool to lock the flywheel in place. If you own a Haynes manual you can look up how to make one yourself. Good luck!
Cheers

[scotyp]

Not sure how long a home mechanic would take, I guess it would depend on skill and tools etc but my mech charged me 3 hrs and that included changing all radiater hoses as well.

Good luck.

Mate I hear what you saying and normally I'd agree, but good help in Airlie beach is hard to find, I got a mechanic to do my clutch which I normally do myself and they stuffed it up, the bearing came out of the fork arm and they didn't touch the flywheel, so thats why the homework.

Cheers

[lewy]

the first time i done mine 200 tdi,it took all day.this time the third i think about 4.i dont take the radiator out but it would help as i end up with no skin on the knuckles,havnt got any special tools,a viscous fan tool will help though,just take your time, theres a good guide here,
http://www.fag.hiof.no/~frodehaa/disco.html, (http://www.fag.hiof.no/%7Efrodehaa/disco.html)
and turn the engine over by hand before you try to start

[nice1guv]

I personally haven't done it, but have seen what is involved.

If was going to attempt it myself (as a first timer), I would allow a FULL day to do it and make sure I had a spare day after in case something went wrong or I needed something I didn't have.

Take lots of photos as you go so that you have a reference if neeeded and don't be in a rush.

Good luck! :D

[87County]

Hi All,

Does any one know how long it takes for a first timer to change a 300 tdi timing belt, I plan on removing the radiator etc, but I believe you also need some special tools or can they be subsituted with other tools,

Thanks in advance

Scotty P

give yourself a free day

have all the replacement parts on hand (incl water pump & "P" gasket, replacement idler bearings, gaskets & belts)

there are pics of the special tooling you will need to make or borrow in the gallery section on this site (I don't know how to link to them from here), but basically the most difficult thing to do is undoing the crankshaft pulley bolt & pulling the harmonic balancer, and then it is a matter of locking the crankshaft and injector pump while you replace and tension the new belt..... there are numerous articles on this

NB the usual home handyman method of putting a spanner on the pulley bolt and hitting the starter to loosen it is unlikely to work on 300tdi

check the condition of the fan bearing and viscous unit (not usually considered to be repairable)


oh, here we are.....

http://www.aulro.com/app/showphoto.php/photo/11428/ppuser/14555

http://www.aulro.com/app/showphoto.php/photo/11429/ppuser/14555

[roverrescue]

"NB the usual home handyman method of putting a spanner on the pulley bolt and hitting the starter to loosen it is unlikely to work on 300tdi"

Hmm, this technique works just fine unless some numnut has welded the crank bolt on???

Removing the rad is helpful for space and if you dont have A/C lets you see align marks more easily but isnt overly necessary. It does give you the chance to change hoses, flush the rad and I/C and of course makes sit easier to get the rattle gun in ;)

Have fun - it aint rocket science. The difflock article is hard to beat for step by step instructions.

Steve

[steveG]

I did mine on the Disco when I first got it last year, but just picked away at over a few days/evenings so cant tell you how long it actually took. I think nice1guv is probably on the money with allow a day and have some time up your sleeve in case it goes pear-shaped.
I had the radiator rodded while it was out (definitely worthwhile if yours hasn't been done for a few years), and did a few other jobs like the P gasket, and intercooler flush while it was out.

Dont forget to get the crank seal (not usually part of the timing belt kit), and also some O rings for the oil cooler pipes where they go into the radiator.

There should be plenty of info here - check the "Good Oil" section for a tutorial, or have a look at the one on Difflock.com.

From memory, the special tools you'll need:
- Viscous hub spanner (and its a LH thread from memory)
- Pump timing pin (or shank of correct size drill bit)
- crank timing pin (can be made out of a bolt)
- tool to hold the crank pulley while you do the bolt back up. From memory the torque is roughly 1 small hernia plus 90degrees. At a pinch, very tight plus 90degrees with a rattle gun works.
To get the bolt undone I found wedging the bar/socket against the chassis and giving the starter a quick flick was the easiest way (with fuel solenoid wire disconnected so it doesn't start).

Its quite a simple job, but I've heard of people having lots of grief when previous mechanics have loctited the crank pulley or bolt on.

Steve

[Blknight.aus]

6 hours to a day depending on how you are with the spanners and what else your doing.

my advice is to start nice and early (0600) so that when something goes pear shaped its still before lunch so you can easily duck down to repco or the likes to get stuff

then if it goes wrong again you should still have enough hours left in the day to go have another visit if needed.

[87County]

"NB the usual home handyman method of putting a spanner on the pulley bolt and hitting the starter to loosen it is unlikely to work on 300tdi"

Hmm, this technique works just fine unless some numnut has welded the crank bolt on???..............
Steve


numnut eh? .... spec for this bolt is 80nm +90 degrees - go figure :o

...be prepared to undo it properly ;)

[Didge]

Sometimes its just easier to do a bit of overtime if its available. Just had one done on the 300tdi and the mechanic didn't need to remove the radiator. He worked over the bullbar as well. Haymes manual has details on tools (like 3/8" drill bit) to lock diesel pump and flywheel. Easy enough job if you can start early and have Sunday up your sleeve. Mechanic did the job in about 1 hour but he's good). Download the RAVE manual (465mB - its got everything in it. If you've got plastic ones allow for brass plugs in the radiator as you'll have to drain that. Possibly also hoses and a new radiator overflow tank (or whatever its called) for $65 if it hasn't already been replaced (they crack along the seal). My mechanic used loctite and just gave the main crank bolt a good old heave (no 80nm here).
I priced the whole timing belt kit (pulleys as well) and was quoted an outrageous $550 just to buy the kit. Got the whole thing installed for $450.
cheers gerald

[d2dave]

Took me about four hours.
When I first purchased my tdi I did not know the history.
At the time I new nothing about the pump timing pin
I had no manuals to follow.
I just put some texta marks on the pulleys and then counted the notches on the belt between marks.
I then fitted new belt the same.
43,000 kays latter and it is still running fine.
The only tool I had to buy was a fan spanner.

Dave.

[Didge]

Sounds like you're in the wrong game. You should be a surgeon. I think I'd need the full weekend without manuals, etc. I need to take someone like you along next time I'm in the bush.

[d2dave]

Sounds like you're in the wrong game. You should be a surgeon. I think I'd need the full weekend without manuals, etc. I need to take someone like you along next time I'm in the bush.

I am a retired spanner.
Where is bush for you I have never head of Engadine.

Dave.

[roverrescue]

87 County, i was not accusing you of being a numnut?

The starter will generate a whole lot more torque than even a grunty 3/4 rattler.
The technique works because it does two things - big torque in a short impulse (cant achieve breaker bar) and effectively holds the crank from turning which can be difficult when using a rattle gun. Im sure there are risks, I presume if you tried hard enough you could burn out your starter. And if you didnt disconnect the fuel solenoid im sure you could have some fun... but as a general rule... it works.

The one case where it wouldnt have worked for me was where I was trying to undo the crank bolt that a previous "mechanic" had MIG glued onto the crank, I guess to make sure it didnt come off.
Judicious grinding first and then the starter did the trick that time.
The thread was fine so Im still a little unsure as to why.

Regards,
S

[zwitter]

Hi
About 4 hours to do the belt, left radiator in place but drained it and stuck cardboard on radiator to protect the fins.

Bought Fan Spanner (32mm ? same as ford)
Bought 27mm 3/4 socket for crank bolt
used locktite to put bolt back on
Used instructions from difflock site
Made thing to hold crank to tighten up the crank bolt (About 2 hours to make)
Bought the timing pins kit and puller off ebay. (franklin?)
Used the starter to undo crank bolt

Biggest problem was i had wrong seal for front timing cover as i have the older version and seal for the new version. Had to wait till monday to get correct one.

My belt had been running true after 100000k and very clean. Put tensioner and pulley kit on.

About to do it again at 160000k

will be quicker next time. I hope it is just the belt this time??

have lent the tools out before to folk on here.

Cheers james

[Didge]

Mr Whippy/ Dave
Engadine is one solid hour south of Sydney and 20mins inland from the coast, so bush for me is anywhere west of the Great Divide, although it's probably still not technically the bush is it?! Especially when you look on the map of the whole country. Still really coastal.
cheers gerald

[awabbit6]

Allow a full day. Take your time and check other things while your at it.
I did mine over two days because I had to replace one of the woodruff keys and didn't request one in the original parts order. The time I spent waiting for a new key was an opportunity to clean some of the excess oil and grime from the front of the motor and inside the timing cover.

[MinniTheMoocha]

Don't forget to allow for the front timing cover bearing being replaced or the whole cover being replaced.

A new cover is expensive $400ish so it might pay to have the right bearing ready to go. Instructions for replacing the bearing is in the tutorials section.

I have done three timing belts now using the difflock guide and my car is still going strong 25,000+ km later.

[gwebb]

Just done mine. 2 hours on Friday night taking it all apart, got stuck when I got to the Harmonic balancer bolt (noise issues in carport while kids were trying to sleep) started at 8 the next morning and was driving by 2.30. I found the hardest part was lining up the belt properly. Had to do it three times and it was a mongrel to fit as its so tight when its new but apart from that it is a straight forward job if you follow the Haymes book.