How to Replace timing belt on Alfa Romeo 156 2.0 TS 16V 2002-2005

Replacement Interval Guide

• Alfa Romeo recommend:
• Balancer shaft belt
• →00 156:
• Replacement every 72,000 miles.
• 147/156 01→:
• Check every 24,000 miles.
• Replacement every 72,000 miles or 5 years.
• →00:
• 145/146/155/166/Spider/GTV:
• Check every 24,000 miles or 2 years.
• Replacement every 72,000 miles or 6 years.
• 01→:
• 166/Spider/GTV:
• Check every 24,000 miles.
• Replacement every 72,000 miles or 5 years.
• Timing belt
• 145/146/155:
• Check every 48,000 miles or 4 years.
• Replacement every 72,000 miles or 6 years.
• 147/166:
• →07/07:
• Replacement every 36,000 miles or 3 years.
• 08/07→:
• Replacement every 36,000 miles or 5 years under normal conditions.
• Replacement every 36,000 miles or 4 years under adverse conditions.
• 156/GTV/Spider:
• Replacement every 36,000 miles or 3 years.
• The previous use and service history of the vehicle must always be taken into account.

Check For Engine Damage

CAUTION: This engine has been identified as an INTERFERENCE engine in which the possibility of valve-to-piston damage in the event of a timing belt failure is MOST LIKELY to occur. A compression check of all cylinders should be performed before removing the cylinder head(s).

Repair Times – hrs

Special Tools

• Camshaft locking tools – Alfa Romeo No.1.825.041.000.
• Inlet camshaft holding tool – Alfa Romeo No.1.822.155.000.
• Exhaust camshaft holding tool – Alfa Romeo No.1.822.146.000/1.822.156.000.
• Timing belt tensioning tool – Alfa Romeo No.1.822.149.000.
• Balancer shaft belt tensioning tool – Alfa Romeo No.1.822.154.000.

Special Precautions

• Disconnect battery earth lead.
• DO NOT turn crankshaft or camshaft when timing belt removed.
• Remove spark plugs to ease turning engine.
• Turn engine in normal direction of rotation (unless otherwise stated).
• DO NOT turn engine via camshaft or other sprockets.
• Observe all tightening torques.
• 
  

  Removal

  1. Raise and support front of vehicle.
  2. Remove:
     • • Engine top cover (if fitted).
       • RH wheel.
       • Engine undershield.
       • RH wheel arch liner.
       • Auxiliary drive belt and tensioner.
       • Crankshaft pulley [1] .
       • Timing belt upper cover [2] .
       • Timing belt lower cover [3] .
       • Ignition coils.
       • Cylinder head cover [5] .
       • Centre spark plug – cylinder No.1.
  3. Insert dial gauge in No.1 cylinder centre spark plug hole [6] .
  4. Turn crankshaft slowly to TDC on No.1 cylinder. Use dial gauge [6] .
  5. Ensure balancer shaft marks aligned [7] & [8] .
  6. Ensure marks on belt aligned with marks on sprockets [9] & [10] .
  7. Slacken balancer shaft belt tensioner nut [11] .
  8. Remove balancer shaft belt and sprocket from crankshaft [4] .
  9. Slacken timing belt tensioner nut [12] .
  10. Remove timing belt.

  Installation

  1. Ensure crankshaft at TDC on No.1 cylinder. Use dial gauge [6] .
  2. Hold camshaft sprockets. Use tool Nos.1.822.155.000 & 1.822.146.000/1.822.156.000 [13] & [14] . Slacken bolt(s) of each camshaft sprocket.
  3. Remove third bearing cap from each camshaft [15] & [16] .NOTE: Mark bearing caps before removal for identification.
  4. Fit locking tools in place of bearing caps [15] & [16] . Tool No.1.825.041.000.NOTE: Ensure locking tools aligned with respective cam profiles to prevent damage. Before fitting belt ensure camshaft sprockets turned fully clockwise.
  5. Fit timing belt in anti-clockwise direction, starting at crankshaft sprocket. Ensure directional arrows point in direction of rotation.
  6. Ensure marks on belt aligned with marks on sprockets [9] & [10] .
  7. Tension timing belt to maximum. Use tool No.1.822.149.000 [17] .
  8. Tighten tensioner nut [12] .
  9. Hold camshaft sprockets. Use tool Nos.1.822.155.000 & 1.822.146.000/1.822.156.000 [13] & [14] .
  10. Tighten bolt(s) of each camshaft sprocket.
      • • (A) Except 147: 100-124 Nm.
        • (B) 147: 108-132 Nm.
        • M6 bolts: 10-13 Nm.
  11. Remove dial gauge and locking tools [6] , [15] & [16] .
  12. Fit bearing caps in correct locations.
  13. Lubricate camshaft bearing cap bolts. Tighten bolts. Except 147: 13-16 Nm. 147: 14-17 Nm.
  14. Turn crankshaft two turns clockwise to TDC on No.1 cylinder [6] .
  15. Fit tensioning tool [17] . Tool No.1.822.149.000.
  16. Slacken tensioner nut [12] .
  17. Turn tensioner anti-clockwise until pointer [18] aligned with hole [19] .
  18. Tighten tensioner nut [12] .
      • • (A) Except 147: 21-26 Nm.
        • (B) 147: 23-28 Nm.
  19. Ensure crankshaft at TDC on No.1 cylinder [6] .
  20. Align balancer shaft timing marks [7] & [8] .
  21. Fit balancer shaft belt and tensioning tool No.1.822.154.000 [20] .
  22. Turn tensioner until hole [21] aligned with centre of tensioner [22] . Tighten tensioner nut [11] .
  23. Turn crankshaft two turns clockwise to TDC on No.1 cylinder [6] .
  24. Ensure timing marks aligned [7] , [8] , [9] & [10] .
  25. Install components in reverse order of removal.
  26. Tighten crankshaft pulley bolts.
      • • (A) Except 147: 24-26 Nm.
        • (B) 147: 23-28 Nm.