Alfa Romeo1999–2006

156 1.6 321.04: Common faults & known problems

Common faults & known problems

21 known faults documented in workshop bulletins. Of these, nine concern the engine and fuel system and three the brakes. Symptoms, causes, repair steps and part numbers are shown where supplied.

Technical specifications

Engine & fuel system

9 documented faults — symptoms, causes and workshop fixes.

Poor driveability from cold

Affects All models, except 1.8/2.0 with two engine coolant temperature (ECT) sensors.Software update

Symptoms

Poor driveability during warm up. Poor idling.

Cause

Engine control module (ECM) software fault.

Repair

Use diagnostic equipment to re-program ECM with upgraded software.

Data: Motorwise Workshop. Bulletin 3.

Water ingress into front footwells

Overview

Affects: All models.

Symptoms

No obvious sign of coolant leakage.

Cause

AC evaporator drain tube blocked by bulkhead sound proofing.

Repair

Cut hole in bulkhead sound proofing to provide outlet for AC evaporator drain tube.
Ensure AC evaporator drain tube not damaged.

Data: Motorwise Workshop. Bulletin 6.

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 8.

Engine overheating

Overview

Affects: All models.
Remedy: Adjust & tighten

Symptoms

Coolant leak from cylinder head gasket.

Cause

Cylinder head bolts too long.

Cylinder head gasket not sealing when specified torque reached.

Repair steps

Ensure engine is cold.
Remove oil in cylinder head.
Remove and replace cylinder head bolts one at a time in order shown.
Tighten new bolts to 40 Nm + 90 ° + 90 ° + 90 °.

Parts

Parts listed in the bulletin
Part	Part number	Qty
Bolt	60677958	10

Data: Motorwise Workshop. Bulletin 10.

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 13.

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 14.

Engine malfunction indicator lamp (MIL) illuminated

Affects All models with 1.9D JTD (937A2.000) engine.P1604Software update

Symptoms

Trouble code stored: P1604.

Cause

Engine control module (ECM) software fault.

Repair

Re-program ECM with modified software.

Data: Motorwise Workshop. Bulletin 15.

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 18.

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 20.

Brakes

3 documented faults — symptoms, causes and workshop fixes.

Front brakes vibrating when brakes applied at medium to high speed

Affects All models, →2000

Cause

Front brake disc distortion.

Repair

Replace front brake pads and brake discs.

Parts4 parts

Parts listed in the bulletin
Part	Part number	Qty
Ventilated disc	60658565	2
Solid disc	60658567	2
Brake pads - ventilated disc	9948334	1
Brake pads - solid disc	9948335	1

Data: Motorwise Workshop. Bulletin 2.

Squeal from rear brakes

Overview

Affects: All models.
Remedy: Clean & lubricate

Cause

Pads seize in brake caliper carrier due to corrosion and dirt ingress.

Repair

Remove and clean rear brake pads.
Clean brake caliper carrier and lubricate.

Data: Motorwise Workshop. Bulletin 7.

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 12.

Suspension & drivetrain

3 documented faults — symptoms, causes and workshop fixes.

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 16.

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 17.

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 19.

Clutch & gearbox

1 documented fault — symptoms, causes and workshop fixes.

Occasional loss of drive

Affects All models with auto shift manual (ASM) transmission.P1769

Symptoms

Trouble code stored in transmission control module (TCM) fault memory: P1769.

Cause

ASM transmission shift actuator accumulator faulty.

Repair

Replace ASM transmission shift actuator accumulator.

Data: Motorwise Workshop. Bulletin 21.

Air conditioning & heating

2 documented faults — symptoms, causes and workshop fixes.

Outlet air distribution/temperature does not correspond to setting

Affects All models with automatic temperature control (ATC).

Cause

Ignition switched ON immediately after reconnection of battery.

AC/heater air mix flap motor and AC/heater air direction motor position cycle interrupted.

Repair

Disconnect battery, reconnect and wait at least 2 minutes before switching ignition ON.

Data: Motorwise Workshop. Bulletin 1.

Engine coolant blower motor only works on second blower speed

Overview

Affects: All models, 1997-02.
Remedy: Clean & lubricate

Symptoms

Engine malfunction indicator lamp (MIL) illuminated.

Cause

Failure of engine coolant blower motor resistor.

Repair

Check and clean engine coolant blower motor resistor multi-plug terminals.
Replace engine coolant blower motor resistor.

Data: Motorwise Workshop. Bulletin 9.

Body & trim

2 documented faults — 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 4.

Noise sounds as though it is coming from behind instrument cluster/fascia, but can be difficult to pin-point

Overview

Affects: All models.

Cause

Sound proofing touching fascia support panel.

Repair

Remove fascia or windscreen.
Cut sound proofing away to avoid contact with fascia support brackets.

Data: Motorwise Workshop. Bulletin 11.

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 5.

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
Nm: Newton-metres — the standard unit for how tightly a bolt is done up
Trouble Codes: Standardised fault codes stored by the engine control module, read with a diagnostic tool
AC: Air conditioning — the system that cools the cabin
ATC: Automatic temperature control — climate control that holds the temperature you set
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
ECT: Engine coolant temperature — the sensor that tells the engine control module how hot the engine is
KS: Knock sensor — listens for engine knock so the engine control module can retard the timing
TCM: Transmission control module — the electronic unit that manages the gearbox
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
Caliper: The part that squeezes the brake pads onto the disc
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
Engine Coolant Temperature: How hot the engine is, read by a sensor the engine control module uses for fuelling and cooling fans
Fascia: The dashboard and the surrounding interior panel
Fault Memory: The list of stored trouble codes in a control module
Multi-Plug: A multi-pin electrical connector on a wiring harness
Oil Gallery: An internal oil passage in the engine
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
Blower Motor: The fan that pushes air through the heater and air-conditioning
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
Evaporator: The air-conditioning heat exchanger in the dashboard that cools the cabin air
Head Gasket: The seal between the cylinder head and the engine block
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 156 1.6?

This guide contains 21 workshop bulletins for the Alfa Romeo 156 1.6. Of these, nine concern the engine and fuel system and three the brakes. Symptoms, causes, repair steps and part numbers are shown where supplied.

Does every Alfa Romeo 156 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 156 1.6 faults myself?

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