How to Replace timing belt on Alfa Romeo 156 1.8 TS 16V 2002-2005

• 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

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.

• Removal

  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.