Alfa 156 2.0 TSpark Timing Belt Replacement

Special Tools
Camshaft locking tools – Alfa Romeo No.1.825.041.000
Inlet camshaft holding tool – Alfa Romeo No.1.822.155.000
Exhaust camshaft holding tool – Alfa Romeo No.1.822.146.000
Timing Belt tensioning tool – Alfa Romeo No.1.822.149.000
Balancer shaft belt tensioning tool – Alfa Romeo No.1.822.154.000

Special Precautions
Disconnect battery earth lead
DO NOT turn crackshaft or camshaft when timing belt removed
Remove spark plugs to ease turning engine
Turn engine in normal direction of rotation
DO NOT turn engine via camshaft or other sprockets
Observe all tightening torques.

Removal (numbers in brackets refer to diagram)
1. Remove:
RH Wheel Engine undershield RH whell arch liner
Auxiliary drive belt and tensioner Crank shaft pulley [1]
Timing belt upper cover [2]
Timing belt lower cover [3]
Ignition coils Cylinder head cover [5] Centre spark plug – cylinder no.1.
2. Insert dial gauge in No.1 cylinder centre plug hole [6]
3. Turn crankshaft slowly to TDC on No.1 cylinder. Use dial gauge [6]
4. Ensure balancer shaft marks aligned [7] & [8]
5. Ensure marks on belt aligned with marks on sprokets [9] & [10]
6. Slacken balancer shaft tensioner nut [11]
7. Remove balancer belt and sprocket from crankshaft [4]
8. Slacken timing belt tensioner nut [12]
9. Remove timing belt

Installation (numbers in brackets refer to diagram)
1. Ensure crankshaft at TDC on No.1 cylinder. Use dial gauge [6]
2. Hold camshaft sprockets. Use tool Nos. 1.822.155.000 and 1.822.146.000 [13] & [14]. Slacken bolt(s) of each camshaft sprocket.
3. Remove third bearing cap from each camshaft [15] & [16]. NOTE: Mark bearing caps before removal from identification.
4. Fit locking tools in place of bearing caps [15] & [16]. Tool No.1.825.041.000.
NOTE: Ensure locking tools aligned with respective cam prfiles to prevent bamage. Before fitting belt, ensure camshaft sprockets turned fully clockwise.
5. Fit timing belt in anto clockwise direction, starting at crannkshaft sprocket. Ensure diectional arrows point in direction of rotation.
6. Ensure marks on belt aligned with marks on sprockets [9] & [10].
7. Tension timing belt to maximum. Use tool No.1.822.149.000 [17].
8. Tighten tensioner nut [12].
9. Hold camshaft sprockets. Use tool Nos.1.822.155.000 & 1.822.146.000 [13] & [14].
10. Tighten bolt(s) of each camshaft sprocket.
(A) Except 146: 100-124 Nm.
(B) 147: 108-132 Nm. M6 Bolts: 10Nm.
11. Remove dial guage and locking tools [6], [15] & [16].
12. Fit bearing caps in correct locations.
13. Lubricate camshaft bearing cap bolts. Tighten bolts. Except 147L 13-16Nm.
147: 14-17Nm.
14. Turn crankshaft turn turns clockwise to TDC on No.1 cylinder [6]. Note: dial gauge will need to be replaced.
15. Fit tensioner tool [17]. Tool No.1.822.149.000.
16. Slacken tensioner nut [12].
17. Turn tensioner anti-clockwise until pointer [18] aligned with hole [19].
18. Tighten tensioner nut [12].
(A) Except 147: 21-26Nm.
(B) 147: 23-28Nm.
19. Ensure crankshaft at TDC on No.1 cylinder [6].
20. Align balancer shaft timing marks [7] & [8]
21. Fit balancer shaft belt and tensioning tool No.1.822.154.000 [20].
22. Turn tensioner until hole [21] aligned with centre of tensioner [22]. Tighten tensioner nut [11].
23. Turn crankshaft two turns clockwise to TDC on No.1 cylinder [6].

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