How to Replace timing belt on Alfa Romeo 156 2.4 JTD 2002-2005

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

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.

  1. Raise and support front of vehicle.
  2. 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.
  3. Fit flywheel locking tool [1] . Tool No.1.820.630.000.
  4. Remove:
     • • Crankshaft pulley bolts [2] .
       • Crankshaft pulley [3] .
       • Timing belt lower cover [4] .
       • Timing belt upper cover [5] .
       • Engine steady bar bracket.
  5. Support engine.
  6. Remove:
     • • RH engine mounting.
       • Flywheel locking tool [1] .
  7. Turn crankshaft clockwise to TDC on No.1 cylinder.
  8. Ensure pin on crankshaft sprocket at 6 o’clock position [6] .
  9. Ensure camshaft sprocket timing marks aligned [7] .
  10. If timing marks not aligned: Turn crankshaft one turn clockwise.
  11. Slacken tensioner sprocket nut [8] . Move tensioner sprocket away from belt. Lightly tighten nut.
  12. Remove timing belt.

  Installation

  1. Ensure pin on crankshaft sprocket at 6 o’clock position [6] .
  2. Remove oil pump housing bolt. Insert stud of crankshaft timing tool [9] . Tool No.1.860.905.010.
  3. Fit timing belt to crankshaft sprocket.
  4. Fit timing tool to crankshaft sprocket [10] . Tool No.1.860.905.000.
  5. Ensure pin on crankshaft sprocket located correctly in tool [11] .
  6. Secure timing tool to crankshaft sprocket with bolt [12] .
  7. Ensure camshaft sprocket timing marks aligned [7] .
  8. 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.

  9. Slacken tensioner sprocket nut [8] .
  10. Lever tensioner sprocket bracket at position [13] until pointer and mark aligned [14] .
  11. Tighten tensioner sprocket nut [8] . Tightening torque: 42-52 Nm.
  12. Remove timing tool [10] .
  13. Turn crankshaft two turns clockwise.
  14. Fit crankshaft timing tool [10] .
  15. Ensure camshaft sprocket timing marks aligned [7] .
  16. Remove crankshaft timing tool [10] .
  17. Fit oil pump housing bolt.
  18. Install components in reverse order of removal.
  19. Tighten crankshaft pulley bolts [2] . Tightening torque: 21-26 Nm.