How to Replace timing belt on Alfa Romeo 156 1.6 TS 16V 2002-2005

Alfa Romeo Belts

Replacement Interval Guide

  • Alfa Romeo recommend:
  • 145/146/155:
  • Check every 48,000 miles or 4 years.
  • Replacement every 72,000 miles or 6 years.
  • 147:
  • →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/Spider/GTV:
  • 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

Remove & install:
145/1462,75
1552,75
1562,25
Spider/GTV2,75

Special Tools

  • 1,4: Camshaft locking tool – Alfa Romeo No.1.825.042.000
  • 1,6 (105 HP/77 kW): Camshaft locking tool – Alfa Romeo No.1.870.797.000.
  • 1,6 (120 HP/88 kW): Camshaft locking tool – Alfa Romeo No.1.870.734.000.
  • 1,8: Camshaft locking tool – Alfa Romeo No.1.825.041.000.
  • Crankshaft sprocket adaptor – Alfa Romeo No.1.820.618.000.
  • Except 147: Inlet camshaft holding tool – Alfa Romeo No.1.822.155.000.
  • 147/156: Inlet camshaft holding tool – Alfa Romeo No.1.822.156.000.
  • Exhaust camshaft holding tool – Alfa Romeo No.1.822.146.000.
  • Timing belt tensioning tool – Alfa Romeo No.1.822.149.000.

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.
    1. Remove:
        • RH front wheel.
        • Engine cover.
        • Auxiliary drive belt.
        • Auxiliary drive belt guide pulley [1] .
        • Crankshaft pulley [2] .
        • Timing belt upper cover [3] .
        • Ignition coils.
        • Cylinder head cover [4] .
        • Centre spark plug – cylinder No.1.
    2. Insert dial gauge in No.1 cylinder centre spark plug hole [5] . Turn crankshaft slowly to TDC on No.1 cylinder.
    3. Ensure marks on belt aligned with marks on sprockets [6] [7] .
    4. Slacken timing belt tensioner nut [8] .
    5. Remove timing belt.NOTE: Mark direction of rotation on belt with chalk if belt is to be reused.

    Installation

    1. Ensure crankshaft at TDC on No.1 cylinder. Use dial gauge [5] .
    2. Hold camshaft sprockets. Except 147: Use tool Nos.1.822.155.000 & 1.822.146.000. 147: Use tool Nos.1.822.156.000 & 1.822.146.000 [9] [10] . Slacken bolt(s) of each camshaft sprocket.
    3. Except 147: Remove third bearing cap from each camshaft [11] [12] .
    4. 147: Remove second inlet camshaft bearing cap and third exhaust camshaft bearing cap [16] [17] .NOTE: Mark bearing caps before removal for identification.
    5. Fit locking tools in place of bearing caps [11] [12] or [16] [17] .
        • 1,4: Tool No.1.825.042.000.
        • 1,6: Tool No.1.870.797.000 or No.1.870.734.000.
        • 1,8: 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.

    6. Fit timing belt in anti-clockwise direction, starting at crankshaft sprocket. Ensure directional arrows point in direction of rotation.
    7. Ensure marks on belt aligned with marks on sprockets [6] [7] .
    8. Tension timing belt to maximum. Use tool No.1.822.149.000 [13] .
    9. Tighten tensioner nut [8] .
    10. Hold camshaft sprockets. Except 147: Use tool Nos.1.822.155.000 & 1.822.146.000. 147: Use tool Nos.1.822.156.000 & 1.822.146.000 [9] [10] .
    11. Tighten bolt(s) of each camshaft sprocket.
        • (A) Except 147: 100-124 Nm.
        • (B) 147: 108-132 Nm.
        • (A) M6 bolts – except 156: 10 Nm.
        • (B) M6 bolts – 156: 12 Nm.
    12. Remove:
        • Dial gauge [5] .
        • Locking tools [11] [12] or [16] [17] .
    13. Fit bearing caps in correct locations.
    14. Lubricate camshaft bearing cap bolts. Tighten bolts. Except 147: 13-16 Nm. 147: 14-17 Nm.
    15. Turn crankshaft two turns clockwise to TDC on No.1 cylinder [6] . 156: Use tool No.1.820.618.000.
    16. Ensure timing marks aligned [6] [7] .
    17. Fit tensioning tool [13] . Tool No.1.822.149.000.
    18. Slacken tensioner nut [8] . Turn tensioner anti-clockwise until pointer [14] aligned with hole [15] .
    19. Tighten tensioner nut [8] .
        • (A) Except 147: 21-26 Nm.
        • (B) 147: 23-28 Nm.
    20. Turn crankshaft two turns clockwise to TDC on No.1 cylinder [6] .
    21. Ensure timing marks aligned [6] [7] .
    22. Install components in reverse order of removal.
    23. Tighten crankshaft pulley bolts. Tightening torque: 24-29 Nm.
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