nedkelly

Guys,

I have read a couple of threads on this site about belt changes. I have just bought a '92 968 Coupe with just under 70,000 Kilometres on it. As all the history is in Japanese (OPC Tokyo) I figure it is best to do the belt change for piece of mind.

I have reasonably good electro-mechanical skills (engineer on Flight Simulators for 20 years) but no experience with these vehicles. So I was going to put the car into a specialist shop for the job. However, before I commit to this I'd like to know if anybody tackled this job for the first time themselves and if so what was the outcome?

Do I need specialist tools for belt tension, bot cam belt and balancer belt? I have bought the belts from OPC already and is there anything else I should be thinking of doing at the same time like tensioner seals etc.

Has anybody drawn up their own procedure or how good is the maintenance manual for this job.

Sorry to go on but I guess I'm apprehensive as it's my first REAL car!

RajDatta

Hello Ned, how are you? I have performed this task atleast 5 different times and plan on doing it again soon.
It does require the P9201 tool to check tension. Hopeully you can rent one. Here is the procedure.
Disconnect battery.
Lift car on stands in the front.
Remove all under body panels that cover the engine.
Disconnect radiator fan connections and remove 6 10mm screws holding the fan to the radiator.
Pull the fan shourd from the bottom.
Loosen both tensioner rods for PS pump belt and laternator belt and remove both belts.
Remove timing/balance shaft belt covers by removing 0mm bolts all around the plastic covers.
Remove gromet from flywheel inspection hole and turn the engine clockwise until you see a feww arrows pointing in direction of cloackwise rotation and then 3 scribe marks after it.
Align the middle scribe mark in the middle of inspection hole.
Remove starter and install flywheel lock.
Use a 24mm deep socket to remove main bolt holding the PS pump pulley and remove it.
Undo balance shaft tensioer and remove balance shaft belt.
Slide the balance shaft gear from bottom on crank together with alternator pulley.
Remove 3 13mm bolts holding hydraulic tensioner and remove it.
Remove timing belt.
To install, you need to 1st compress the tensioner into a wise. Take you time and use a big washer to protect the tensioner.
Install a pin to hold compressed tensioner in place as it has a hole to align it.
Installation is reverse of removal.
Check your water pump for play while in there.
I might have missed a few steps but I completely going by memmory.
Other can add if I missed something.
Raj



D

josephsc

Ned, welcome to the list!

I guess you've noticed that there's alot of information to be found -- almost too much info -- by going through the threads (the search function is very handy for this). You'll also find more info over on 968.net.

As for tool, IIRC, You'll need a flywheel lock and a pin spanner, but the jury is still out on P9201 vs Kriket/Optibelt (but most seem to be fine with the Kriket).

As for the procedures, Haynes manual is useless for belt change, but head over to http://www.clarks-garage.com/ and click on Garage Shop Manuals, and you'll find what you need there.

My Japanese is rusty, but I'd be happy to translate it for you, if you'll put me on a flight to Dubai!

nedkelly

Raj,

Thanks for the info. I am assuming you have plenty of mechanical experience having done this task before. I think I will have a go at this after I can ascertain if I can get a loan/hire of the tension checking tool.

Josephsc,

Thank you also for your input. I can certainly put you on a flight to Dubai but as for paying for the same........................close but no cigar, sorry. I'll check out your link and let you know how it all goes.

Checking for play in the water pump is a case of rocking it side to side I guess.

RajDatta

Joe, as far as finding info on other sites, look who the authors usually were .
Raj

josephsc

That's a good warning -- on the other board, I tend to not trust any posts in the last 6 months...

nedkelly

Okay guys,
as i am quite a virgin when it comes to these forum thingy's would you like to enlighten me!?

RajDatta

Ned, lets put it this way, you are doing just fine. You should be able to have all your questions answered here.
You will also need the flywheel lock tool which is not that expensive.
Raj

nedkelly

With all the help I've had in only a week of ownership I feel like I own the biggest workshop manual in the world..........a zillion thank you's!

God this car puts a smile on my face It goes like a train and changes direction like it's on rails. Here in Dubai there is a lot of expensive Lambo's, Ferrari's and top of the line Porsches but mine still turns heads and I've had a lot of nice comments

RajDatta

Catch them Lambo's and Ferrari's on twisties and you will look even better. Might even get a compliment or two from the owners of those cars .
Raj

Derek H

Ned,

This is a personal thing and others will disagree but I don't think the tensioner tool is necessary, especially on a 968, which has the auto tensioner for the cam belt, that prevents manual tension setting anyway. I've done belt changes on all my own 16V P-cars (944S, 2 x 944S2, 2 x 968), and a couple of belt changes for other people, and I've always been comfortable going by feel. Having said that, I'm an engineer by profession and I did loads of car maintenance when I was younger as a sideline income.

I've seen massive variation in balance shaft belt tension on different cars and I'm convinced that the majority of 944 variants (including 968's) are running around with the balance belt tension way off. Even those with full OPC service history! Hence, my own preference is to set by feel, and check regularly. I pull the belt covers at least every 6,000 miles for a quick looksee (not perfect, but gives an idea). Only takes half an hour or so.

The balance belt tension is noticeably less than the cam belt and I'd think that if you have any mechanical engineering background, you'd be able to set this just fine. Be aware though, that the balance belt needs retensioning after 3-4000 kms (IIRC, it's in the service schedule). This is not just precautionary, it really will need retensioning. Trust me! Also, it will need retensioning at every 12,000 mile service, in my experience.

cheers
Derek

nedkelly

Derek,

Thanks for your input. In your opinion, what deflection should I be looking for for cambelt vs balancer belt? Where on the belt run should the delection be checked?

Cheers,

josephsc

That reminds me, Ned, you have PM! (Private Mail -- under "my profile")