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

Alfa Romeo

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

Remove & install:
145/146/1552,90
1562,95
1663,10
Spider/GTV2,90

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.
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