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How to Replace timing belt on Alfa Romeo 156 2.5 24V 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

Remove & install:
156 3,45
166 4,70
GTV 4,50
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.
How to Replace timing belt on Alfa Romeo 156 2.5 24V 2002-2005
How to Replace timing belt on Alfa Romeo 156 2.5 24V 2002-2005

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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