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

Alfa Romeo

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

Remove & install:
1563,45
1664,70
GTV4,50
GTV (with AC)+0,90

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.
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