Alfa Romeo2004–2011

147 1.6: Common faults & known problems

Common faults & known problems

19 known faults documented in workshop bulletins. Of these, five concern the engine and fuel system and three the electrical and ignition. Symptoms, causes, repair steps and part numbers are shown where supplied.

Technical specifications

Engine & fuel system

5 documented faults — symptoms, causes and workshop fixes.

Engine misfire

Water/oil ingress into spark plug orifice. Fix: clean and lubricate.

Overview

Affects: All models.
Remedy: Clean & lubricate

Symptoms

Engine malfunction indicator lamp (MIL) illuminated. Poor cold starting. Poor engine running.

Repair steps

Clean ignition coil and spark plug orifice.
Check spark plugs for insulator damage or arcing.
Check cylinder head cover for leaks.

Data: Motorwise Workshop. Bulletin 4.

Failure to start

Overview

Affects: All models.

Symptoms

Failure to start when engine is hot. Trouble code stored in engine control module (ECM) fault memory.

Cause

Faulty crankshaft position (CKP) sensor.

Repair

Replace crankshaft position (CKP) sensor.
Access engine control module (ECM) fault memory and erase trouble codes.

Data: Motorwise Workshop. Bulletin 7.

Idle speed surges

Throttle valve not closing correctly due to build up of deposits in throttle body. Fix: clean and lubricate.

Overview

Affects: All models.
Remedy: Clean & lubricate

Symptoms

Engine jerking. Poor throttle response.

Repair steps

Remove throttle body intake pipe.
Clean deposits from inner wall.
Actuate throttle valve manually 3 to 5 times.
Inspect throttle body for any remaining contamination.
If necessary clean again.
Fit throttle body intake pipe.
Check idle speed.

Data: Motorwise Workshop. Bulletin 8.

Engine malfunction indicator lamp (MIL) illuminated

Affects All models with petrol engines.P0325P1325

Symptoms

Trouble codes stored: P0325, P1325.

Cause

Knock sensor (KS) fault.

Repair

Check wiring connector and resistance of KS. Replace parts as necessary.

Data: Motorwise Workshop. Bulletin 14.

Rattling noise from top of engine for several seconds when starting after the vehicle has stood for long periods

Overview

Affects: All models with 1.6/1.8/2.0 petrol engines.
Remedy: Fit modified part
Parts: 4 parts

Cause

Camshaft position (CMP) actuator drains after standing for long period.

Oil non-return valve not included at manufacture.

Repair

Engine No. →3575550. Remove cylinder head. Fit non-return valve to oil gallery of camshaft position (CMP) actuator. Refit cylinder head. Fit modified camshaft position (CMP) actuator. Fit new cylinder head cover gasket.
Engine No. 3575550→. Fit modified camshaft position (CMP) actuator. Fit new cylinder head cover gasket.

Parts4 parts

Parts listed in the bulletin
Part	Part number	Qty
Camshaft position (CMP) actuator	71738360	1
Non-return valve	60677899	1
Cylinder head cover gasket (JTS)	60669492	1
Cylinder head cover gasket (Twin spark)	60655592	1

Data: Motorwise Workshop. Bulletin 19.

Electrical & ignition

3 documented faults — symptoms, causes and workshop fixes.

Condensation in front indicator lamps

Affects VIN 3235929-5141453.

Cause

Bulb holder's seal missing.

Repair

Replace bulb holder as necessary.

Parts1 part

Parts listed in the bulletin
Part	Part number	Qty
Bulb holder	50500965	1

Data: Motorwise Workshop. Bulletin 6.

Rear fog lamp failure warning lamp illuminated

Overview

Affects: All models.
Remedy: Fit modified part
Parts: 2 parts

Cause

Rear fog lamp bulb holder faulty.

Repair

Remove rear fog lamp.
Fit modified rear fog lamp.

Parts2 parts

Parts listed in the bulletin
Part	Part number	Qty
Rear fog lamp	46747826	RHD
Rear fog lamp	46556346	LHD

Data: Motorwise Workshop. Bulletin 11.

Airbag warning lamp illuminates permanently or intermittently

Poor connection of side airbag harness multi-plug under front seats. Fix: fit a modified part.

Overview

Affects: All models with side airbags, VIN →5234543.
Remedy: Fit modified part

Repair steps

Locate orange side airbag harness multi-plug under front seats.
Cut wires 10 mm both sides of harness multi-plug. Only cut one wire at a time.
Fit modified harness multi-plug by soldering wires together and insulate using heatshrink sleeves.
Secure harness multi-plug to underside of seat using multi-plug mounting bracket and cable tie.

Parts

Parts listed in the bulletin
Part	Part number	Qty
Harness multi-plug kit	50507402	1
Multi-plug mounting bracket - LH	51790883	1
Multi-plug mounting bracket - RH	51790884	1

Data: Motorwise Workshop. Bulletin 18.

Brakes

2 documented faults — symptoms, causes and workshop fixes.

Squeaking noise from rear brakes

Affects All models.

Cause

Handbrake cable sticking due to internal damage/corrosion.

Repair

Replace both handbrake cables.

Data: Motorwise Workshop. Bulletin 5.

Premature operation of electronic stability program (ESP)

Overview

Affects: All models: VIN 3327094-3354034. VIN 5213889-5234805.
Remedy: Fit new part
Parts: 1 part

Cause

ABS/ESP control module software fault.

Repair

Carry out electrical, mechanical and component tests (as applicable) to eliminate any other possible cause(s).
If no fault(s) found: Fit new ABS/ESP control module.

Parts1 part

Parts listed in the bulletin
Part	Part number	Qty
ABS/ESP control module	71747779	1

Data: Motorwise Workshop. Bulletin 16.

Suspension & drivetrain

3 documented faults — symptoms, causes and workshop fixes.

Knocking/squeaking noise from rear suspension over uneven surfaces

Affects All models.

Cause

Rear trailing arm hub assembly bushes.

Repair

Replace both rear trailing arm hub assembly bushes.

Data: Motorwise Workshop. Bulletin 9.

Knocking noise from front suspension over uneven surfaces

Affects All models.Fit modified part

Cause

Excessive play between front inner anti-roll bar bushes and bush clamps.

Repair

Fit modified front anti-roll bar.

Data: Motorwise Workshop. Bulletin 10.

Knocking/squeaking noise from rear suspension over uneven surfaces

Rear suspension lower arm bushes worn. Fix: fit a new part.

Overview

Affects: All models.
Remedy: Fit new part

Repair steps

Mark position of rear suspension lower arm inner bolt.
Fit new rear suspension lower arms.
Realign marks and check rear wheel alignment.

Data: Motorwise Workshop. Bulletin 13.

Clutch & gearbox

1 documented fault — symptoms, causes and workshop fixes.

Gear lever does not self-centre

Gear selection mechanism seized. Fix: clean and lubricate.

Overview

Affects: 1.6/2.0 with 5-speed gearbox.
Remedy: Clean & lubricate

Repair steps

Remove gear selection mechanism from gearbox.
Clean corrosion from gear selection mechanism.
Renew and lubricate gear selection mechanism bushes.

Data: Motorwise Workshop. Bulletin 3.

Air conditioning & heating

1 documented fault — symptoms, causes and workshop fixes.

Air conditioning (AC)/heater flap motors do not relate to AC control settings

Affects All models with manual temperature control.B1801

Symptoms

AC/heater function control panel symbols not illuminated. Trouble code stored: B1801 (AC/heater air mix flap motor, malfunction).

Cause

Failure of AC/heater function control panel symbol bulbs.

Repair

Replace all bulbs in AC/heater function control panel.

Parts1 part

Parts listed in the bulletin
Part	Part number	Qty
Bulb	71747970	3

Data: Motorwise Workshop. Bulletin 17.

Body & trim

1 documented fault — symptoms, causes and workshop fixes.

Bonnet not opening or closing correctly

Affects All models.Clean & lubricate

Cause

Bonnet catch seized.

Repair

Clean and lubricate bonnet catch.

Data: Motorwise Workshop. Bulletin 1.

Wipers & visibility

1 documented fault — symptoms, causes and workshop fixes.

Noise from lower windscreen area

Overview

Affects: All models.
Remedy: Clean & lubricate

Cause

Dry contact surfaces on front suspension upper arm bushes.

Front suspension upper arm bushes worn.

Repair

Check front suspension upper arm bushes for excessive play.
Replace or lubricate front suspension upper arm bushes as necessary.

Data: Motorwise Workshop. Bulletin 2.

Other

2 documented faults — symptoms, causes and workshop fixes.

Metallic noise from fascia over uneven road

Affects All models, →02/05.

Symptoms

Rattling noise from audio unit area.

Cause

Excessive clearance between audio unit and surrounding.

Repair

Apply felt tape to audio unit.

Data: Motorwise Workshop. Bulletin 12.

The message "ODO" flashes in the trip meter display

Overview

Affects: All models.

Cause

Loss of communication between control modules.

Repair

Reset multifunction control module.
Diagnostic equipment required.

Data: Motorwise Workshop. Bulletin 15.

Glossary

Technical terms used in this guide.

MIL: Malfunction indicator lamp — the engine warning light on the dashboard
ECM: Engine control module — the electronic unit that manages the engine
VIN: Vehicle identification number — 17 characters, found at the base of the windscreen and on the V5C logbook
Trouble Codes: Standardised fault codes stored by the engine control module, read with a diagnostic tool
ABS/ESP: Anti-lock braking and electronic stability programme — the system that stops the wheels locking and keeps the vehicle stable
CKP: Crankshaft position sensor — tells the engine control module where the crankshaft is in its rotation
CMP: Camshaft position — a sensor that tells the engine control module where the camshaft is
KS: Knock sensor — listens for engine knock so the engine control module can retard the timing
AC/Heater: The heating and air-conditioning system
Actuator: A motor or solenoid that moves a mechanical part on command
Anti-Roll Bar: A bar that links the left and right suspension to cut body roll in corners
Control Module: A control unit for one of the vehicle's systems (engine, gearbox, brakes, body, and so on)
Crankshaft Position: Where the crankshaft is in its rotation — used for ignition and injection timing
Fault Memory: The list of stored trouble codes in a control module
Multi-Plug: A multi-pin electrical connector on a wiring harness
Multifunction Control Module: The control module that runs shared electrical functions (lights, wipers, locking, and so on)
Oil Gallery: An internal oil passage in the engine
Trouble Code: A standardised fault code stored by a control module, read with a diagnostic tool
Bush: A rubber mounting that lets a suspension or body joint move without metal-to-metal contact
Bushes: Rubber mountings that let a suspension or body joint move without metal-to-metal contact
Lower Arm: A suspension link that locates the wheel at the bottom of the hub

Frequently asked questions

What are the common faults with the Alfa Romeo 147 1.6?

This guide contains 19 workshop bulletins for the Alfa Romeo 147 1.6. Of these, five concern the engine and fuel system and three the electrical and ignition. Symptoms, causes, repair steps and part numbers are shown where supplied.

Does every Alfa Romeo 147 1.6 have these faults?

No. These are patterns documented across the model by workshops, not predictions for an individual vehicle. Where a fault applies only to certain vehicles or VIN ranges, that is listed with the fault.

Can I check for Alfa Romeo 147 1.6 faults myself?

Many of them. The documented symptoms can be seen, heard or felt during a test drive.