How to Replace timing belt on Alfa Romeo 156 3.2 GTA 2002-2005

Replacement Interval Guide

• Alfa Romeo recommend:
• 156/GTV:
• →12/00:
• Replacement every 72,000 miles or 5 years under normal conditions.
• Replacement every 72,000 miles or 3 years under adverse conditions.
• 01/01→:
• 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:
• →12/00:
• Replacement every 72,000 miles or 5 years.
• 01/01-08/03:
• 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(s).

Repair Times – hrs

Special Tools

• Camshaft locking tools (2,5/3,0) – Alfa Romeo No.1825040000.
• Camshaft locking tools (3,2) – Alfa Romeo No.1870849000.
• Camshaft sprocket puller – Alfa Romeo No.1860954001.
• Crankshaft pulley locking tool – Alfa Romeo No.1870646000.
• Dial gauge and adaptor – Alfa Romeo No.1825013000.
• Flywheel locking tool (GTV 1997) – Alfa Romeo No.1820088000.
• Sprocket holding tool – Alfa Romeo No.1822146000.
• Timing belt tensioning tool – Alfa Romeo No.1860950000

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:
     • • 166/GTV: Engine upper cover(s).
       • RH front wheel.
       • Inner wing panel.
  3. Turn auxiliary drive belt tensioner anti-clockwise [1] .
  4. Lock auxiliary drive belt tensioner. Use suitable pin.
  5. Remove:
     • • Auxiliary drive belt.
       • Auxiliary drive belt tensioner.
       • GTV: Auxiliary drive belt guide pulley.
       • 166: PAS reservoir and bracket.
       • Inlet manifold [2] .
       • Ignition coils cover [3] .
       • Ignition coils [4] .
       • Cylinder head covers [5] .
       • Timing belt upper cover [6] .
       • Timing belt lower covers [7] .
       • Spark plug – cylinder No.1.
       • GTV 1997: Exhaust downpipe.
       • GTV 1997: Flywheel cover.
  6. Except GTV 1997: Fit crankshaft pulley locking tool. Tool No.1870646000.
  7. GTV 1997: Fit flywheel locking tool. Tool No.1820088000.
  8. Slacken crankshaft pulley nut [20] .
  9. Remove:
     • • Locking tool. Tool No.1870646000 or 1820088000.
       • Crankshaft pulley [8] .
  10. Fit dial gauge and adaptor to No.1 cylinder [9] . Tool No.1825013000.
  11. Turn crankshaft clockwise until No.1 cylinder at TDC of compression stroke. Use dial gauge.
  12. Slacken timing belt tensioner bolts [10] .
  13. Remove timing belt.

  Installation

  1. Ensure No.1 cylinder at TDC of compression stroke. Use dial gauge [9] .
  2. Remove four camshaft bearing caps [11] .NOTE: Mark bearing caps before removal for identification.
  3. Fit locking tools in place of bearing caps [11] .
     • • 2,5/3,0: Tool No.1825040000.
       • 3,2: Tool No.1870849000.

     NOTE: Ensure locking tools aligned with respective cam profiles to prevent damage.

  4. GTV: Remove engine steady bar and bracket.
  5. Hold camshaft sprockets. Use tool No.1822146000 [12] .
  6. Slacken bolt of each camshaft sprocket [13] & [14] .
  7. Ensure camshaft sprockets can turn freely without tilting.
  8. If not: Use puller. Tool No.1860954001.
  9. Fit timing belt in anti-clockwise direction, starting at crankshaft sprocket.
  10. GTV 1997:
      • • Support engine.
        • Remove bolts securing rear gearbox mounting to crossmember.
        • Lower rear of engine slightly.
  11. Remove:
      • • Lower alternator bolt.
        • Water pump bolt.
  12. Fit tensioning tool [15] . Tool No.1860950000.NOTE: Ensure tensioning tool correctly located on tensioner lever [16] .
  13. Turn tensioning tool nut [17] until notch on lever positioned below fixed mark [18] .
  14. Hold camshaft sprockets. Use tool No.1822146000 [12] .
  15. Tighten bolt of each camshaft sprocket [13] & [14] . Tightening torque: 68-84 Nm.
  16. Remove:
      • • Camshaft locking tools [11] .
        • Dial gauge and adaptor [9] .
  17. Lubricate and fit bearing caps in correct locations.
  18. Tighten bearing cap bolts to 18-20 Nm.
  19. Turn crankshaft two turns clockwise.
  20. Check tensioner marks aligned [19] .
  21. If not: Turn tensioning tool nut [17] until marks aligned.
  22. Tighten tensioner bolts [10] . Tightening torque: 17-21 Nm.
  23. Remove tensioning tool [15] .
  24. Install components in reverse order of removal.
  25. Tighten crankshaft pulley nut [20] . Tightening torque: 200-247 Nm.