Changing Timing Belts on a 200 TDI, The Easy way

**sclarke** · 15th January 2005, 10:28 PM

Today i thought i'd better change the timing belt on the 200 TDI Disco as the Tubo Volvo just broke its and i now have a dead Volvo.

So i went down to Four Wheel Drive in Blackburn Victoria and bought the bits required.
Belt, Gasket, Seal, Waterpump gasket, Tensioner and idler pully.
$300 odd buck later i was driving home and planning my Weekend

I Dropped into All Tools in Ringwood Vic and bought a 3/4" L shapped bar and a 3/4" Drive 30mm 6 sided socket for the Crank. That was $90

Then i got home and sorted out the problem on holding the Crank.
I ended up making a fantastic tool that works a treat. I'll post pix on the Gallery with dimensions so you can all make one.
I cheated as i used a disco pully as the main part of the tool.

I then started stripping the alternator, waterpump, power steer and Aircond untill the front of the engine was bare.

I then used my super tool on the crank and undid the Crank bolt with the tools i bought and a 2 meter square Tube and lots of effort to crack it.

I then had a bigger problem arrise. 1 of the 4 bolts that hold the pulley on the crank was stripped so i could not undo it.

I was still able to use the New puller i imported to remove the crank pulley/damper it was not easy but it came off. I then had to drill the head of the bolt and then i could remove the pulley from the damper. The damper could then be reused as the bolt just un screwed.

Cause was me using a 12 pointed socket. ONLY USE 6 SIDED SOCKETS on the 10mm Bolts.

I then replaced the Idler pully and tensioner and Belt and Seal and Gasket and then reassembled it after using emery on the Damper shaft to make sure the seal would be good.

I timed it all up and turned it over a few times with no wire on the injector pump then retensioned it all up.

It was straight forward but i had a few headaches.

Things i did to make it easier.
Cut the Fan Cowl at the bottom so you can split the cowl and feed it over the fan, saves work in the future.
Use only 6 pointed sockets on the 10mm and Crank bolts
Make a tool to hold the crank (it hits the chassis so the crank wont turn)

I'll be posting Pix of the tools and the process i took.

After that i did me snorkle.....

Regards
Steve

**Tiny** · 16th January 2005, 01:33 AM

Giday Steve - sorry to hear about your Volvo, but I'm looking forward to seeing your "tool" :-)

I've nearly got my 300TDi finished - just some electrics to sort out and then see if I've done my timing belt replacement properly as well!

Cheers,

**LandyAndy** · 16th January 2005, 01:36 PM

A simple method of un-doing crankshaft bolts that wont budge,a tad on the rough side but it does work when you are stuck.
Get a socket on the crank bolt and a bar,position the bar so it is an inch or so away from hitting the drivers side chassis,make sure it wont hit anything else,crank the engine on the starter(with coil or diesel system disabled so it doesnt start up)Hey persto,the nut is loosened.
Andrew

**Ace** · 16th January 2005, 01:44 PM

I assume you have tried it LA, you didnt have trouble with the bolt heads stripping? Sounds simple though, and it requires no huffing and puffing, i like it. Matt

**LandyAndy** · 16th January 2005, 02:22 PM

Last time I did it was on an EA Falcoon also had to do it on the trytoo once.You shouldnt strip the bolt head with the correct socket,they are usually high quality bolts on the end of a crank.
Andrew

**Ace** · 16th January 2005, 07:57 PM

Originally posted by LandyAndy
Last time I did it was on an EA Falcoon also had to do it on the trytoo once.You shouldnt strip the bolt head with the correct socket,they are usually high quality bolts on the end of a crank.
Andrew

Thanks, mine has only just been done, but will keep it in mind for when it does need doing. Matt

**sclarke** · 16th January 2005, 10:18 PM

Photo's have just been updated in the Gallery
Go to

"volvo164 AKA Clarkie"
"Modifications and repairs"

Regards
Steve

Thread: Changing Timing Belts on a 200 TDI, The Easy way

Thread Tools

Changing Timing Belts on a 200 TDI, The Easy way

Bookmarks

Bookmarks

Posting Permissions