My '96 960 with 161K miles is overdue for a Timing Belt replacement. I neither have the facility nor ability to do the work myself but I do have an honest and reputable mechanic to do the job for me.

My question is this: In addition to the Timing Belt, what other components should I have replaced while the cover is off ? Tensioner, Pulleys, Water Pump?
Are there tell-tale signs that these components need to be replaced or is it just a matter of milage and wear?

Approximately how many hours of labor should I allow for this work to be completed and what is a fair estimate for this project?

Have I left out any components from the following list that I should order for the Timing Belt Replacement project?

1. Timing Belt, 2. T/Belt Tensioner,3. T/Belt Tensioner Roller, 4.T-Belt Idler,
5. Front Camshaft Seal, 6.Front Crank Seal, 7. Water Pump, 8. Serpentine Belt

It is unlikely you will need to replace seals. In the event that you do, it complicates the procedure significantly as the cam pulleys need to come off and that really requires the factory cam setting tools to do it right.

The factory tools attach to the back of the cams so that means the position sensor on the exhaust and the cover on the intake need to come off. The crankshaft lock used with the cam tool requires the starter to be removed also.

Some people have done this by carefully marking the pulley positions on the cams but that has got to be an inaccurate method.

I would think the normal stuff, (belt, idlers, tensioner & pump) can be accomplished in less than 2 hours.
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'96 965, 16" wheels, Michelin Pilot Sports, rear 18mm bar + Koni, 204HP cams, 128K. Put 200K on '85 745 TD.

I don't believe the camshaft seals are necessary unless they are leaking.

DEWFPO
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1998 S90 071,245 and 1995 964 154,100

Many thanks all for your experienced advice on what components to change along with the timing belt. Approximately how much time (hours) should I allow/expect to complete this work?

Also, can I find specific instructions for performing this work in the FAQ section?

The specific instructions are, indeed, in the faq. Click here to reference them.

At the risk of being repetitive and redundant and repeating myself, make sure your mechanic is aware that this is an interference engine. Meaning, he needs to rotate the crankshaft by hand through two complete revolutions before engaging the starter after he's installed the new belt. This ensures that no valves are colliding with the piston due to incorrect installation.

All the part save the water pump are supposed to be replaced at the 2nd interval (140k). I would do all the timing belt stuff as well as the water pump since it is right there after you remove the belt. I wouldnt wait too long to do it since you are already 20k over.
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97 S90 with 184K miles still going strong

I agree with Poolman, at 161K, I would change the following parts : tensioner, tensioner pulley, idler pulley along with the belt. If you've got the spare cash, you can change out the water pump. I check all pulleys for noise, wobble, roughness and sound. If I dectect anything (anythinh at all), I replace it. The new pulleys will be very smooth rolling with no noise or play of any kind. Changing out the pulleys doesn't really take more than an additional 10 minutes or so since you got everything apart.

DEWFPO
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1998 S90 071,245 and 1995 964 154,100

I changed mine at about the same mileage that you have on yours--here's what I found- the belt wheels were getting pretty bad on their bearings-replaced them all-the belt tensioner was the original-replaced as well-if your on the origanal water pump replace that part also-the serpintine belt that drives the power steering and alternator ect- replaced along with the wheel on the tensioner for that part.
In all your going to have around 3-4 hundred in parts depending who you get them from-I ordered all the parts ahead of time from Grotton and replaced them out, as I was sure they couldn't hurt, to have new parts in there.
Hope that helps
Poolman