Cam belt failure... timing question! - Alfa Romeo Forum
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Help Cam belt failure... timing question!

Got a lovely 2004 156 2.4 jtd 20v... that decided a cambelt was additional to its requirements at motorway speeds the other day.

I've got a little experience with engines so gonna try DIY it back together.

So I've removed the rocker cover/cam carrier and found myself a half dozen broken rocker arms... I've then put a bore scope down the injector holes and the pistons all seem to look ok, no real markings from valves that i can see - valves themselves i cant see as the mirror for my scope won't fit. tops of the stems all seem to sit at the same height so i'm going to assume all good...

what you think? foolish? i really don't fancy removing the head - looks like a big job...

So when i buy myself some new rockers and a timing kit ill need to bolt the rocker cover on - so main question is, how do you set the timing on the crank and cam to put the two back together? i see a mark on both the pulleys but not sure where they align to?

advice appreciated as i'm sure these rockers arent going to be cheap... in fact, anyone know what alfa charge? will try gsf/eurocarparts as well i suppose!

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Dont remove the head!!!! The rockers are designed to break so should be no other damage. You can time these engines on the marks but as your belt has gone you are probably best buying the locking set (I think I paid about 50) which consists of two locking pins for the cams and a crank locking plate. Make sure you replace water pump as these are weak and it would ruin your day if it went soon after the rebuild. Also carefully check all the aux pulleys (especially the spring loaded one) as these can be a source of problems.

Autolusso sell a complete kit for the 16V on their website so I'm sure they can get you the bits they need for your 20V. Good luck.

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dont remove head ..replace all rockers turn crank to tdc (remove glow plugs to releave compression) new water pump new belt tensioner and marked belt to markings on cam and crank
ps get tdc before putting new rockers on
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Give us a ring tomorrow we keep rockers in stock for these at a big discount off Alfa retail - 01582 869 560. You will also need injector seals (cheap), a cam carrier gasket, timing belt kit and a water pump.

By the way, was it a seized waterpump that caused the failure? Thats usually the case. Valve/piston damage is very rare, but can sometimes happen. Have any of the needle bearings split? If so, you must make sure to get every last single one out, make sure you count them out. They often drop down into the sump. If none have split, thats good news

Autolusso Penrith - UK's leading independent Alfa Romeo specialist with branches in Bedfordshire, Cumbria & Dorset

Wizard Exhaust systems available here

Tel: 01768 879 171
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By the way, you need the locking tools to double check everything is correct - we've seen cams shift in the cam carrier before which is again quite rare but does happen, you don't want to have to do the job twice.
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