Description and Preparation:
Firstly, when doing timing belt change for the 2.0TS/JTS 16v engine, we always recommend replacing all the related parts which includes:
- timing belt
- timing fixed tensioner
- timing adjustable tensioner
- balancer belt
- balancer tensioner
- auxiliary belt
- auxiliary fixed tensioner
- auxiliary adjustable tensioner
Second of all, we recommend change of timing belt before the 60,000km interval recommended by the agent. We have seen many cases of the timing belt breaking just after the 60,000km interval or before that!
The 1.6Ts 16v engines do not have balancer shafts, so the it is not necessary for 2 of the parts mentioned above - balancer belt and balancer tensioner. Breakage of the timing belt means a very big repair bill job as all the valves will snap or bend, so never try your luck by delaying the job.
Besides the parts mentioned above, you will also need an Alfa Romeo special tool comprises of two locking tools (see picture) for the camshafts and a dial gauge to find top dead centre position.
Various Alfa Romeo 4Cyl Cam Locking Tools
First thing to do is to remove the engine cover which is secured by 4 ribe screws, next is to remove the cam cover (secured by 3 screws on earlier models with an alloy cam cover and 4 screws on late models with plastic cam cover). The spark plug caps can then be carefully removed and put to one side. The rocker cover is now ready to come off. Once this has been successfully removed the camshafts are visible and the locking tools have to be fitted to cylinders 2 and 3 this may involve rotating the engine. Number 1 spark plug on number 1 cylinder needs to be removed and the DTI should be fitted down its hole.
Next we have to remove the right hand front wheel, under tray and wheel arch liner to gain access to the front right side cover of the engine, which housed the timing and balancer belts. To do this we have to remove the auxiliary belt by using a spanner to slacken the adjustable tensioner and then remove the belt. Once the auxiliary belt is removed, proceed to remove adjustable and fixed auxiliary tensioner to replace them. Next remove the screws on the cover to expose the belts.
Now we can remove the timing and balancer belt by loosening the centre bolts of the tensioners. You will note while you are doing this that both the timing and balancer tensioners are made of plastic and they will also need to be replaced as they have a tendency to break which has the same effect as a timing belt breaking as the belt goes loose and slips over the cam wheels.
The idler (fixed tensioner) on the opposite side of the timing belt will also need to be replaced as it is usually noisy. If your car is hitting 120,000km for its second timing belt change, we suggest to replace the water pump at this point as it is easy at this point in time. If the water pump fail and need replacement in the future you will have to go through the same whole process above just to replace it.
To refit the timing belt you reverse the process, however there are some points to note, the first of these is you need to slacken the centre bolts of both the inlet and exhaust cam pulleys so they are able to move a little and then tighten the timing belt using the timing belt tensioner before re-tightening the centre bolts on the cam shafts. You will then need to fit the balancer shaft belt and to do this you align the marks on the belt with the marks on the pulleys you are now in a position to fit all the other parts back on.