300tdi timing belt replacement

Replacing the timing belt always sounds like a scary job to do by yourself, I remember the first time I did it by myself, I had to install it 3 times till I understood what I’m doing wrong.

Anyway, replacing the 300tdi timing belt is not that hard to do, actually, the hardest part is pulling out the engine pulley.

The easiest way to do it is by removing the radiator so you’ll have a lot of space, but, in most cases, you won’t want to do it as it involves a lot of work.

Required tools:

Thin 32 or 36 mm spanner wrench will be used to remove the fan clutch – the original size is 32mm, some replaced it over the years and it might be a 36 mm.

10mm socket and spanner wrench

27mm socket

15mm socket

Torque wrench that shows the current torque

13mm socket/spanner wrench to remove the A/C compressor.

Parts:

300 tdi Timing Kit

You may want to replace the front oil seal as well.

Let’s start working…

1. Remove the fan clutch: locate the 32mm on the fun clutch nut, using a hammer, hit the wrench clockwise and remove the fan clutch completely. Be careful not to damage the radiator.

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2. Now it’s the tough part… Open the 27mm bolt that hold the crank shaft pulley (pulley wrench could be helpful, worst case solution is to remove the radiator and use an impact driver to open it)

3. Remove the engine belts, remove the fan clutch pulley (4x 10mm bolts).

4. Remove the crank pulley, you will probably need a pulley puller. Pay attention, there is a spline that holds the pulley in place, it is a small part, try not to lose it. If you did lose it, here it is 🙂

5. Remove the timing cover. they are all 10mm bolts most of them in different lengths :), keep track which goes where…

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6. Remove the timing cover

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7. Replace the Idler, tensioner (Allen socket for both) and crankshaft pulley – you will need a puller for that one (see the image below, puller and Allen bolts) .

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8. Place each part in its place, do not tighten them yet. Install the new belt. Make sure that the crankshaft pulley spline points to “12 o’clock”, the camshaft pulley points to the mark on the side and the diesel pump is locked in the correct position – use a 9mm drill to hold it in place. See the picture below:

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Tight the idler pulley to 45 NM.

Tension the timing belt to 15NM (for a new belt, old belt should be 12 NM)

Tight the tensioner to 45 NM.

Using a wrench, turn the engine complete 2 turns (make sure the ignition is off), verify noting get stuck…

Install everything back in place, besides the fan clutch, Use the “inspection window” in the timing cover to fine tune the diesel pump, 3x 10mm bolts, few mm play to each side, turn the pump and see the smoke amount, easy starting and power.

Good luck…