Replacement Interval Guide
- Alfa Romeo recommend:
- 156:
- Check every 36,000 miles.
- Replacement every 72,000 miles or 5 years under normal conditions.
- Replacement every 72,000 miles or 3 years under adverse conditions.
- 166:
- →08/03:
- Check every 36,000 miles.
- Replacement every 72,000 miles or 5 years.
- 09/03-04/06:
- Check every 36,000 miles.
- Replacement every 72,000 miles or 5 years under normal conditions.
- Replacement every 72,000 miles or 3 years under adverse conditions.
- 05/06→:
- Check every 36,000 miles.
- Replacement every 72,000 miles or 5 years under normal conditions.
- Replacement every 72,000 miles or 4 years under adverse conditions.
- 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.
Repair Times – hrs
Remove & install | 2,00 |
Special Tools
- Auxiliary drive belt tensioner locking pin – No.1.870.645.000.
- Crankshaft timing tool – No.1.860.905.000.
- Crankshaft timing tool stud – No.1.860.905.010.
- Flywheel locking tool – No.1.820.630.000.
Special Precautions
- Disconnect battery earth lead.
- DO NOT turn crankshaft or camshaft when timing belt removed.
- Remove glow 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
NOTE: The high-pressure fuel pump fitted to this engine does not require timing.
- Raise and support front of vehicle.
- Remove:
- Engine upper cover.
- Engine undershield.
- RH front wheel.
- RH inner wing panel.
- Auxiliary drive belt. Use tool No.1.870.645.000.
- Flywheel housing lower cover.
- Fit flywheel locking tool [1] . Tool No.1.820.630.000.
- Remove:
- Crankshaft pulley bolts [2] .
- Crankshaft pulley [3] .
- Timing belt lower cover [4] .
- Timing belt upper cover [5] .
- Engine steady bar bracket.
- Support engine.
- Remove:
- RH engine mounting.
- Flywheel locking tool [1] .
- Turn crankshaft clockwise to TDC on No.1 cylinder.
- Ensure pin on crankshaft sprocket at 6 o’clock position [6] .
- Ensure camshaft sprocket timing marks aligned [7] .
- If timing marks not aligned: Turn crankshaft one turn clockwise.
- Slacken tensioner sprocket nut [8] . Move tensioner sprocket away from belt. Lightly tighten nut.
- Remove timing belt.
Installation
- Ensure pin on crankshaft sprocket at 6 o’clock position [6] .
- Remove oil pump housing bolt. Insert stud of crankshaft timing tool [9] . Tool No.1.860.905.010.
- Fit timing belt to crankshaft sprocket.
- Fit timing tool to crankshaft sprocket [10] . Tool No.1.860.905.000.
- Ensure pin on crankshaft sprocket located correctly in tool [11] .
- Secure timing tool to crankshaft sprocket with bolt [12] .
- Ensure camshaft sprocket timing marks aligned [7] .
- Fit timing belt in following order:
- Guide pulley.
- Camshaft sprocket.
- High-pressure fuel pump sprocket.
- Tensioner sprocket.
- Water pump pulley.
NOTE: Ensure belt is taut between sprockets on non-tensioned side.
- Slacken tensioner sprocket nut [8] .
- Lever tensioner sprocket bracket at position [13] until pointer and mark aligned [14] .
- Tighten tensioner sprocket nut [8] . Tightening torque: 42-52 Nm.
- Remove timing tool [10] .
- Turn crankshaft two turns clockwise.
- Fit crankshaft timing tool [10] .
- Ensure camshaft sprocket timing marks aligned [7] .
- Remove crankshaft timing tool [10] .
- Fit oil pump housing bolt.
- Install components in reverse order of removal.
- Tighten crankshaft pulley bolts [2] . Tightening torque: 21-26 Nm.
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