Alfa Romeo2005–2010

147 1.9 JTDM 8V: 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 suspension and drivetrain. Symptoms, causes, repair steps and part numbers are shown where supplied.

Technical specifications

Engine & fuel system

5 documented faults — symptoms, causes and workshop fixes.

Excessive noise from turbocharger (TC)

Overview

Affects: All models.
Remedy: Clean & lubricate

Symptoms

Damage to the bearing running surfaces. Oil leak from turbocharger (TC).

Cause

Oil supply pipe banjo bolt filter blocked.

Repair

Inspect turbocharger (TC) for damage, replace if necessary.
Check and clean filter inside oil supply pipe banjo bolt.

Data: Motorwise Workshop. Bulletin 3.

Engine jerking

Exhaust gas recirculation (EGR) valve not operating properly.

Overview

Affects: All models with 1.9D JTD 8V/16V/2.4D JTD 20V engines.

Symptoms

Hesitation when accelerating at 1800-2000rpm.

Repair steps

Check operation of thermostat.
Check engine oil level correct.
Check for contamination of fuel.
Check fuel filter.
Check whole intake system for leaks.
Check mass air flow (MAF) sensor.
Check for oil in intake system.
Check fuel injectors for leaks.
Check fuel injectors for correct type.
Ensure EGR system operates correctly.
Remove EGR valve and fit restrictor plate: 1.9D JTD 16V/2.4D JTD 20V 1.9D JTD 8V.

Parts

Parts listed in the bulletin
Part	Part number	Qty
Restrictor plate	71751468	1,9D JTD 16V/2,4D JTD 20V
Gasket	55191883	1,9D JTD 16V/2,4D JTD 20V
Restrictor plate	71751469	1,9D JTD 8V
Gasket	46773082	1,9D JTD 8V

Data: Motorwise Workshop. Bulletin 9.

Abnormal noise from engine bay when engine idling or between 1400-2100rpm

Unsatisfactory design of fuel pipe between fuel filter and high-pressure fuel pump. Fix: fit a new part.

Overview

Affects: All models, →2006.
Remedy: Fit new part

Repair steps

Replace fuel filter (16V engine).
Fit new fuel pipe between fuel filter and high-pressure fuel pump.
Re-position fuel pipe mounting clip on fuel filter housing approximately 35 mm closer to high-pressure fuel pump.

Parts

Parts listed in the bulletin
Part	Part number	Qty
Fuel pipe	50505349	8V engine
Fuel pipe	50505492	16V engine
Fuel filter	50505495	16V engine
Retaining clip	46773576	All models

Data: Motorwise Workshop. Bulletin 16.

Engine malfunction indicator lamp (MIL) illuminated

Overview

Affects: All models, →04/07.
Remedy: Software update

Symptoms

Digital multifunction display shows 'ENGINE MANAGEMENT SYSTEM FAILURE'.

Cause

Engine control module (ECM) software fault.

Repair

Carry out electrical, mechanical and component tests (as applicable) to eliminate any other possible cause(s).
If no fault(s) found: Re-program ECM with upgraded software.

Data: Motorwise Workshop. Bulletin 17.

Engine malfunction indicator lamp (MIL) illuminated

Overview

Affects: All models with Diesel engines.
Fault codes: P0237P0238P2562P2563

Symptoms

Lack of power. Possible trouble codes stored: P0237, P0238, P2562, P2563. Whistling noise from engine. White smoke coming from exhaust.

Cause

Turbocharger (TC) control pressure sensor faulty.

Internal failure of turbocharger (TC).

Repair

Carry out electrical, mechanical and component tests (as applicable) to eliminate any other possible cause(s).
If no fault(s) found: Replace turbocharger (TC) and turbocharger (TC) control pressure sensor.

Data: Motorwise Workshop. Bulletin 19.

Electrical & ignition

2 documented faults — symptoms, causes and workshop fixes.

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 7.

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 15.

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 4.

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 13.

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 5.

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 6.

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 10.

Clutch & gearbox

1 documented fault — symptoms, causes and workshop fixes.

Heavy clutch pedal action when clutch assembly hot

Affects All models with diesel engines and manual transmission, VIN 3264290-3346069.Fit new part

Symptoms

Stiff, jerky clutch operation when hot.

Cause

Clutch release bearing sticks on guide sleeve due to insufficient lubrication.

Repair

Fit new clutch pressure plate and clutch release bearing.

Data: Motorwise Workshop. Bulletin 12.

Air conditioning & heating

2 documented faults — 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 14.

Engine malfunction indicator lamp (MIL) illuminated

Intake manifold air control actuator faulty. Fix: fit a new part.

Overview

Affects: All models with 1.9 Diesel engine (engine No. →4689071).
Fault codes: P2004P2013
Remedy: Fit new part

Symptoms

Trouble codes stored: P2004, P2013

Repair steps

Erase trouble codes from ECM fault memory.
Initialise intake manifold air control actuator as follows: Switch ignition ON. Switch ignition OFF. Wait 15 seconds.
Repeat above procedure ten times.
Check for trouble codes.
If trouble codes P2004 and/or P2013 present, fit new intake manifold air control actuator.

Parts

Parts listed in the bulletin
Part	Part number	Qty
Intake manifold air control actuator	555205127	1

Data: Motorwise Workshop. Bulletin 18.

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 8.

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 11.

Glossary

Technical terms used in this guide.

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
EGR: Exhaust gas recirculation — feeds some exhaust gas back into the intake to cut emissions
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
MAF: Mass air flow — a sensor that measures how much air the engine is breathing
TC: Turbocharger — the exhaust-driven compressor that boosts engine power
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)
EGR Valve: The valve that meters exhaust gas back into the intake
Fault Memory: The list of stored trouble codes in a control module
Intake Manifold: The housing that distributes air into the cylinders
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)
Re-Program: Update the software on a control module using the manufacturer's diagnostic tool
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
Initialise: A workshop procedure that teaches a new module or system its starting values
Lower Arm: A suspension link that locates the wheel at the bottom of the hub
Recirculation: Air-conditioning mode that recirculates cabin air instead of drawing in outside air

Frequently asked questions

What are the common faults with the Alfa Romeo 147 1.9 JTDM 8V?

This guide contains 19 workshop bulletins for the Alfa Romeo 147 1.9 JTDM 8V. Of these, five concern the engine and fuel system and three the suspension and drivetrain. Symptoms, causes, repair steps and part numbers are shown where supplied.

Does every Alfa Romeo 147 1.9 JTDM 8V 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 1.9 JTDM 8V faults myself?

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