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How to Replace timing belt on Alfa Romeo 156 1.9 JTD 16V 2002-2005

Replacement Interval Guide

  • Alfa Romeo recommend:
  • 147/GT:
  • Check every 36,000 miles.
  • Replacement every 72,000 miles or 5 years under normal conditions.
  • →04/06:
  • Replacement every 72,000 miles or 3 years under adverse conditions.
  • 05/06→:
  • Replacement every 72,000 miles or 4 years under adverse conditions.
  • 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.
  • 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 & install 2,40

Special Tools

  • Crankshaft timing tool – Alfa Romeo No.1.860.905.000.
  • Crankshaft timing tool bolt – Alfa Romeo No.1.860.905.010.
  • Exhaust camshaft locking tool – Alfa Romeo No.1.870.986.900.
  • Sprocket holding tool.

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.
How to Replace timing belt on Alfa Romeo 156 1.9 JTD 16V 2002-2005
How to Replace timing belt on Alfa Romeo 156 1.9 JTD 16V 2002-2005

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 upper torque reaction link bolts [1] .
      • Engine upper torque reaction link [2] .
      • Engine control module (ECM).
      • RH front wheel.
      • Engine undershield.
      • RH wheel arch liner.
      • Auxiliary drive belt.
      • Crankshaft pulley bolts [3] .
      • Crankshaft pulley [4] .
      • Auxiliary drive belt guide pulley.
      • Timing belt upper covers [5] .
      • Timing belt lower cover [6] .
      • Engine upper torque reaction link bracket bolts [7] & [8] .
      • Engine upper torque reaction link bracket [9] .
  3. Turn crankshaft clockwise to setting position.
  4. Ensure pin on crankshaft sprocket at position shown [10] .
  5. Remove blanking plug [11] .
  6. Fit exhaust camshaft locking tool [12] . Tool No.1.870.986.900. Ensure camshaft locked with tool [12] .
  7. Slacken tensioner sprocket nut [13] . Move tensioner sprocket away from belt. Lightly tighten nut.
  8. Remove timing belt.

Installation

  1. Ensure exhaust camshaft locked with tool [12] .
  2. Ensure pin on crankshaft sprocket at position shown [10] .
  3. Hold exhaust camshaft sprocket. Use suitable holding tool.
  4. Slacken exhaust camshaft sprocket bolt [14] .
  5. Remove oil pump housing bolt. Insert stud of crankshaft timing tool [15] . Tool No.1.860.905.000.
  6. Fit timing belt to crankshaft sprocket.
  7. Fit timing tool to crankshaft sprocket [16] . Tool No.1.860.905.000.
  8. Ensure pin on crankshaft sprocket located correctly in tool [17] .
  9. Secure timing tool to stud with nut [18] .
  10. Secure timing tool to crankshaft sprocket with bolt [19] . Tool No.1.860.905.010.
  11. Fit timing belt to remaining sprockets.

    NOTE: Ensure belt is taut between sprockets on non-tensioned side.

  12. Slacken tensioner sprocket nut [13] .
  13. Lever tensioner sprocket bracket at position [20] until pointer and mark aligned [21] .
  14. Tighten tensioner sprocket nut [13] . Tightening torque:
      • (A) M8 – 23-28 Nm.
      • (B) M10 – 42-52 Nm.
  15. Hold exhaust camshaft sprocket. Use suitable holding tool.
  16. Tighten exhaust camshaft sprocket bolt [14] . Tightening torque: 108-132 Nm.
  17. Remove:
      • Timing tool [16] .
      • Locking tool [12] .
  18. Turn crankshaft two turns clockwise.
  19. Fit crankshaft timing tool [16] .
  20. Fit exhaust camshaft locking tool [12] . Ensure camshaft locked with tool [12] .
  21. Ensure tensioner sprocket pointer and mark aligned [21] .
  22. Remove:
      • Timing tool [16] .
      • Locking tool [12] .
  23. Fit oil pump housing bolt.
  24. Fit blanking plug [11] .
  25. Install components in reverse order of removal.
  26. Tighten engine upper torque reaction link bracket bolts [7] & [8] . Tightening torque: 45-55 Nm.
  27. Tighten engine upper torque reaction link bolts [1] . Tightening torque: 45-55 Nm.
  28. Tighten crankshaft pulley bolts [3] . Tightening torque: 23-28 Nm.

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