Timing Belt Change on 1.6 TS
I have just done the timing belt on my 1.6 TS and I thought I would share my experience for the benefit of others. My engine is the 120 BHP with code 321.04, other variants may be different.
I have the cam lock tools but not a dial gauge and adapter for finding TDC. There is a timing mark on the crank pulley and the timing belt cover (which it turns out is very accurate) but I was worried about getting the TDC perfect. On this engine though it turns out you don't need a dial gauge. The solutions is:
1) Lock the exhaust and inlet cams TDC using the tools, loosen the 4 bolts on the inlet cam sprocket. The exhaust sprocket is keyed so it can't be set wrong and this is the key to this method.
2) There are TDC timing marks on both the exhaust (at about 2 o'clock) and the crank (at about 9 o'clock) sprockets. The Dayco belt has lines printed on it that line up to these marks. Therefore if your exhaust sprocket can't be wrong (because it is keyed and the cam is locked with the tool) and you line up both lines on the belt with the corresponding marks on the sprockets then the crank can't be wrong either and must therefore be at perfect TDC.
3) The inlet cam is then simply a case of tightening the 4 locking bolts on the sprocket and you are good to go.
Other variants of the TS engine may not have a keyed exhaust sprocket and so this method won't work but it does on the 321.04 engine and it saves you buying the TDC dial gauge.
It turns out that my engine has had the timing belt change previously and the inlet cam was not perfectly aligned. Now it is the difference is quite noticeable so it is well worth taking you time and getting it all pin on.
Finally the nut on my tensioner looked like a old style castle nut. I don't know if Alfa fit these as standard but if they do then do yourself a favour and change it for a good old nylock nut.
Good luck all and hopefully this will help another Alfa newbie like me.