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

Alfa Romeo

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 & install2,00

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.

    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.
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