200TDi Timing belt DIY replacement

[Elips]

I'm planning to replace timing belt on my 1992 D90 200TDi by myself. I got factory and Haynes manual, but I would like to know how difficult the job really is. Are the special tools really required or can it be done without them? Are there any other parts except the belt that have to be replaced, like gaskets, seals, tensioners.. etc? The engine has 230000 km on the clock, I have no records of previous maintenance so I'm replacing the belt as a precaution.

[crajo]

I wouldnt mind knowing myself but i have a 300 tdi same Kms. Hows things in Croatia. I spent alot of time there 90-95 and i do miss it. where in Croatia are you?
Regards
Craig

[Elips]

I'm in Rijeka. Well, everything is much better nowdays that those gloomy years of early '90... If you ever come back I'm sure you'll like it...

[crajo]

Been there heaps to get on and off the ferry, spent a few days hanging out there resting with a girl friend i met in Dubrovnik. I would love to come back and spend some time wondering around, maybe i will drive the 110 from Australia to the UK to see my family and pop in for a beer
Craig.
Ps No one seems to have replied to your post apart from me. Come on chaps give us some info

[Elips]

Well, I got the belt, gaskets are on their way, as soon as weather gets a bit warmer I'll start taking the bits off... So watch out for "HELP how do I put everything back" type of posts here...

[Blackdown4x4]

Hello mate,

I would advise changing the tensioner as well, and yes the spaecial tools are required you can buy a kit with timing pins and crank puller. Then follow the book and it is pretty straight forward.

Any problems drop me a line.

Regards

Dave

[worms]

I'll be interested to hear how you get on. My local mechanic who is really good with complex agricultural equipment reckoned it was no job for an amateur. The professionals that I am about to go to say that they often find it worth replacing the oil pump while they are in there. I'd be interested to know whether this is just to rack up the cost.

[Elips]

Well, I was hoping I'll get away without special tools... has anyone tried to fabricate special tool LRT-12-044 out of the wading plug by drilling the hole through the center? That's the thingy that blocks flywheel in reqired position while changing the belt...

[scoobymick]

The crank timing tool LRT-12-044 isn't absolutely necessary,when you have the front cover off,use a mirror and look just above the crank gear and you will see an arrow cast into the housing.This arrow should line up with the woodruff key if the timing is right.

Originally Posted by Elips

Well, I was hoping I'll get away without special tools... has anyone tried to fabricate special tool LRT-12-044 out of the wading plug by drilling the hole through the center? That's the thingy that blocks flywheel in reqired position while changing the belt...

[Elips]

Done! I've changed the belt. It was a bit hard and dirty job and took two weekends! Well, now it seems that I could do it in a day... The funniest thing is that the shop where I almost bought the (replacement) belt offered free installation!

I've posted some progress pics on
http://free-ri.t-com.hr/elips/timingbelt/

Comments and criticism welcome!

[Elips]

Originally Posted by worms

The professionals that I am about to go to say that they often find it worth replacing the oil pump while they are in there. I'd be interested to know whether this is just to rack up the cost.

I don't see why, because removing parts to get to the timing belt won't get you any closer to the oil pump which is located somewhere inside oil pan.