Maintenance priority list for 1990 T3

[Vodim]

Hi everyone,

I’d appreciate some advice on creating a sensible priority list for maintenance on my 1990 VW T3 (original 1.6 TD JX engine).

I’m trying to decide what jobs I should prioritize over the coming months to keep the van reliable and avoid expensive failures.

One thing I recently discovered is that the timing belt (cam belt / toothed belt) was last replaced in 1998, at around 109,000 km. The van has now done roughly 190,000 km.

Because of that, my current thinking is that replacing the timing belt is priority number one, simply because of both age and mileage. Does that seem like a sensible assessment to you?

Apart from that, I’d really appreciate help ranking other maintenance items that would be wise to address sooner rather than later.

Some current context:

- The van runs well overall and is used regularly
- Gear linkage renovated last summer
- I’ve had intermittent starting issues (click from starter solenoid but no crank), though after cleaning connections and reinstalling the starter it currently starts fine.
- Original engine (JX 1.6 TD).
- General goal is long-term reliability rather than restoration perfection.

If you were making a priority list for this van, what would your top 5 maintenance jobs be after the timing belt?

Thanks in advance!

[clift_d]

I'd probably start with all new fluids - engine oil, coolant, gearbox oil, brake fluid, power steering fluid, and all new filters - air intake, oil, fuel and power steering reservoir. I'd also check brake pads / discs / etc, and I'd probably also consider changing the other belts - auxiliary (water pump and alternator) and power steering pump - the chances are that if the timing belt hasn't been changed since '98 then the other belts haven't been changed for some time.

It would also be worth reviewing tyre condition and age - they obviously check this in the MOT but it would be sensible for you to have an idea of their condition and how soon any might require replacement. I'd also probably consider replacing the fuel hoses, even if there are no visible signs of cracking. Check the engine bay, and the road under your new van, for signs of leaks that might point to other problems, and do a visual check of any wiring for fraying or similar. Given that it's a diesel I'd also suggest that you also get a small bottle of Marine16 diesel bug treatment and give your fuel system a one-off "kill shot".

Moving forward you might want to start looking at perishables like the suspension bushings and steering couplings, all of which will also help with handling, and maybe going over your fuel system including fully draining and cleaning your tank.

Ideally, you're looking to get all the main maintenance items back to zero so you know their provenance.

[davidoft1]

Cam belt first if it’s genuinely not been changed for 20 years , then all the normal car stuff brakes tyres suspension etc, check wiring , fuel lines don’t suffer on diesels like petrol but worth a check , most of the original fuel line is poly so no issues there

[silverbullet]

Timing belt first.
Renew brake flexi hoses and change brake fluid.
Inspect/renew wheel bearings and brake pads/discs/shoes/drums.
Engine oil and filter service.
Change coolant.

[firetrader]

All the posts seem sensible, clearly if the Cam belt is so old then its got to be top of the list, the rest of he work mentioned in posts seem logical too. Good luck with it, I had a spell of not paying enough attention to maintenance a few years ago due to all sorts of family issues, came back to haunt me as I had to replace the engine an all sorts of parts. They are great vans so worth the effort and money.

[Vodim]

Thanks for the replies, it helps a lot.

About changing the cam/timing belt. What parts exactly are wise to change in that operation? Belt, tensioner and water pump? I think I have seen kits with these parts included.

[davidoft1]

Thanks for the replies, it helps a lot.

About changing the cam/timing belt. What parts exactly are wise to change in that operation? Belt, tensioner and water pump? I think I have seen kits with these parts included.

Timing belt and tensioner, unlike more modern vehicles the cam belt doesn’t run the water pump so it’s easy enough to change and not disturb the cam belt

[mioba]

Better get an order in at brickwerks.

JX - then check valve lash while you are in there.

15w-40 mineral is the way. Tensioner is a must.

All easy jobs to do with Bentley at hand.

Remember the rule if it ain't broke - don't fix it.

[davidoft1]

Better get an order in at brickwerks.

JX - then check valve lash while you are in there.

15w-40 mineral is the way. Tensioner is a must.

All easy jobs to do with Bentley at hand.

Remember the rule if it ain't broke - don't fix it.

Semi synthetic for turbo diesels

[mioba]

Lets not start an oil thread eh.

[Vodim]

Many thanks again!

Received the belt and tensioner today so will start working on it as soon as I can. Read through the Bentley chapter on this and understood roughly what to do. Do I need the special tools they mention or can I get by on home made solutions (except for the torque wrench of course).

[clift_d]

Assuming you can get the engine to TDC, and the camshaft and injection pump properly locked in position, then the only real tricky bit is getting the tension on the belt right, which is supposed to be done using a tension gauge - the VAG tool reference is VW210, but equivalent tools were also made by Hazet, Klann, Laser and others. The following are the Klann instructions on how to use the tool - my understanding is that you need to aim for a tension reading of 12 - 13.



The other thing to watch is that you rotate the tensioner roller the correct way - which I understand is clockwise. The roller will tension the belt in both directions but if you set it in the wrong direction my understanding is that it can lead to the belt running out of true.

I've sent you a download link for the JX engine manuals - Bentley was compiled for the US market and so it doesn't have any information on the TD engine as they didn't sell it there.

[Vodim]

These gauges seem to be hard to get by and sometimes cost a fortune. Best alternative so far is this one:

https://www.hs-werkzeughandel.de/de/Zah ... W-210.html

If no one says that it does not look like the right gauge, I will order it. Regarding the other special tools mentioned in the Bentley manual (2065A, pin 2064) I should be fine without them?

[clift_d]

Locking sets are readily available, so it might just be easier to get one rather than try improvise. Dieselkontor in Germany do a locking set that replaces 2064 and 2065A - see here. Brickwerks also do a similar set but Dieselkontor may be easier for you in the EU.

That tension gauge you have linked would probably be okay - the VW version is a plastic contraption that anyway doesn't seem very robust. I've also seen some discussion on various forums regarding methods for determining tension by twisting the belt but I couldn't speak to their effectiveness.

The pin wrenches that are needed to tension the belt are readily available.

[mioba]

You can get a fuel pump timing set pff ebay for less which includes the above and gague for doing the fuel pump which needs doing when you in there.