How To Change The TS Timing Belt - Alfa Romeo Forum
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(Post Link) post #1 of 14 Old 13-10-07 Thread Starter
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How To Change The TS Timing Belt

In detail, hope its helpful guys.

=====================================

Alfa 156 2.0 TSpark Timing Belt Replacement

Repair Time – Remove and install 2.95 hrs


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 crankshaft or camshaft when timing belt removed
�� Remove sparkplugs 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 attached diagram)
1. Remove:
�� RH Wheel
�� Engine under shield
�� RH wheel arch liner
�� Auxiliary drive belt and tensioner
�� Crankshaft pulley [1]
�� Timing belt upper cover [2]
�� Timing belt lower cover [3]
�� Ignition coils
�� Cylinder head cover [5[
�� Center spark plug – cylinder no.1
2. Insert dial gauge in No.1 cylinder center 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 sprockets [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 profiles to
prevent damage. Before fitting belt, ensure camshaft sprockets turned
fully clockwise.
5. Fit timing belt in ante clockwise direction, starting at crankshaft sprocket.
Ensure directional 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 gauge 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 center of tensioner [22]. Tighten
tensioner nut [11].
23. Turn crankshaft two turns clockwise to TDC on No.1 cylinder [6].
24. Ensure timing marks aligned [7], [8], [9] and [10].
25. Install components in reverse order of removal.
26. Tighten crankshaft pulley bolts.
a. Except 147: 24-26Nm.
b. 147: 23-28Nm.


Cheers!
Attached Images
File Type: jpg TS_Cam.jpg (97.9 KB, 459 views)
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(Post Link) post #2 of 14 Old 13-10-07 Thread Starter
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Re: How To Change The TS Timing Belt

I know there are a lot of special tools, but at least it shows what needs done and how long it should take.
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Re: How To Change The TS Timing Belt

Dead easy eh?
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Re: How To Change The TS Timing Belt

I said it was in detail, not that it was easy LOL

In defense also - it begs the question why it costs hundreds of pounds when the official time for a garage to do it is 3 hours...


Everything is easy if you have the tools, take it step by step, and nothing is seized or breaks during the job.
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Re: How To Change The TS Timing Belt

That makes it sound a lot more complicated than it really is... The only special tools I used was the cam locks.

Tensioners can be tightened with a screwdriver as a lever if you are careful. The balance belt tensioner needs a swan neck spanner, and I used a modified socket with a bar welded to it for the auxillary belt tensioner.

I didn't use the dial gauge to set TDC either, I used the mark on the bottom pulley.
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Re: How To Change The TS Timing Belt

Quote:
Originally Posted by symonh2000 View Post
That makes it sound a lot more complicated than it really is... The only special tools I used was the cam locks.

Tensioners can be tightened with a screwdriver as a lever if you are careful. The balance belt tensioner needs a swan neck spanner, and I used a modified socket with a bar welded to it for the auxillary belt tensioner.

I didn't use the dial gauge to set TDC either, I used the mark on the bottom pulley.
Totally agree, this is from an "official" source of info so quotes the AR method, but its a lot easier doing it your self anyway than fixing after it breaks and better than shelling out 500 to a garage. (if you can do it, I know a lot of folk wouldnt try anything like this)

Maybe those who are about to get it done as a service item should mention they know the official time is 3 hrs labour tho, and not get stitched up for a huge bill to replace it.
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Re: How To Change The TS Timing Belt

Agree wit SymonH.: For a complete, straightforward version, with easy to follow illustrations, Alfa Workshop, (Jamie) with minimal requirements. Check Alfa Workshops back postings, or Gazza's as well. That printed rendition, is well over the top, for a relatively straightford routine operation. No probs. were there, SymonH?:

Last edited by zulu ferret; 13-10-07 at 21:54.
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Re: How To Change The TS Timing Belt

Zzzzzzzzzzzzzzzzzzz
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Re: How To Change The TS Timing Belt

Quote:
Originally Posted by zulu ferret View Post
Agree wit SymonH.: For a complete, straightforward version, with easy to follow illustrations, Alfa Workshop, (Jamie) with minimal requirements. Check Alfa Workshops back postings, or Gazza's as well. That printed irendition, is well over the top, for a relatively straightford routine operation. No probs. were there, SymonH?:
Well I have done 3 of them now with no problems. I still take nearer 5 hours plus a couple of tea breaks to do it mind. If you do your own car you always take that bit more time.

These are the instructions I followed.

http://home.hccnet.nl/jaap.bouma/PhaseVariator.htm

Even this has a few bits missed, you don't need to slacken the exhaust pulley either, its a waste of time as it is keyed.

Simon.
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Re: How To Change The TS Timing Belt

Sorry Mate, didn't mean to send you to kip! Keep posting, Mate, makes life interesting.
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Re: How To Change The TS Timing Belt

Quote:
Originally Posted by zulu ferret View Post
Sorry Mate, didn't mean to send you to kip! Keep posting, Mate, makes life interesting.
LOL cheers mate, was meant to be funny but maybe didnt come across that way now i look at it

( I do seem to get shot down over Normandy sometimes on here lol )
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Re: How To Change The TS Timing Belt

Only thing I don't get, is why different figures are quoted for tightening torques on the 147.......surely all the TS engines are essentially the same......why the difference for the 147?

Richard
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Re: How To Change The TS Timing Belt

dunno, maybe the shorter chassis called for tighter bolts - weird.
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Re: How To Change The TS Timing Belt

Have to ask the Alfa engineering design team on this one.: Use the info from the CD I've got, thinking, rough idea, it's about right, bolt type, length, diameter, thread, for torque and so on.:
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