Alfa Romeo2004–2006

156 1.9 JTD 16V: Common faults & known problems

Common faults & known problems

15 known faults documented in workshop bulletins. Of these, six 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

6 documented faults — symptoms, causes and workshop fixes.

Engine malfunction indicator lamp (MIL) illuminates when starting engine from cold

Glow plug control module faulty.

Overview

Affects
All models, VIN 00260753-00265978, 01320558-01366144.

Repair steps

  1. Check date code.
  2. If date code is not between 18/03/2004 and 21/04/2004, glow plug control module is OK.
  3. If date code is between 18/03/2004 and 21/04/2004 inclusive, replace glow plug control module using part listed.

Parts

Parts listed in the bulletin
PartPart numberQty
Glow plug control module551930731

Data: Motorwise Workshop. Bulletin 2.

Poor starting when engine is hot

Affects All models, VIN 00246800-00270335, 01342413-01373043.Software update

Cause

Engine control module (ECM) software mapping fault.

Repair

  1. Use diagnostic equipment to re-program ECM with upgraded software.
Parts1 part
Parts listed in the bulletin
PartPart numberQty
Upgraded software18065630001

Data: Motorwise Workshop. Bulletin 3.

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

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

Data: Motorwise Workshop. Bulletin 7.

Engine misfire

Overview

Affects
1.9D JTDM/JTD 16V: Engine code 937A5.000, engine No.5853303→.2.4D JTD 20V: Engine code 939A3.000, engine No.5753255→.2.4D JTD 20V: Engine code 939A9.000, engine No.5741021→.
Fault codes
P0201P0202P0203P0204P0205
Parts
2 parts

Symptoms

Engine malfunction indicator lamp (MIL) illuminated. Poor engine performance. Smoke from exhaust. Trouble codes stored: P0201, P0202, P0203, P0204, P0205.

Cause

Poor connection on fuel injector multi-plugs due to vibration.

Repair

  1. Remove top engine cover.
  2. Fit vibration dampers to fuel injector pipes: 1.9D JTDM/JTD 16V 2.4D JTD 20V.
Parts2 parts
Parts listed in the bulletin
PartPart numberQty
Vibration damper552144031,9D JTDM/JTD 16V
Vibration damper552144032,4D JTD 20V

Data: Motorwise Workshop. Bulletin 9.

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

  1. Re-program ECM with modified software.

Data: Motorwise Workshop. Bulletin 10.

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

  1. Check operation of thermostat.
  2. Check engine oil level correct.
  3. Check for contamination of fuel.
  4. Check fuel filter.
  5. Check whole intake system for leaks.
  6. Check mass air flow (MAF) sensor.
  7. Check for oil in intake system.
  8. Check fuel injectors for leaks.
  9. Check fuel injectors for correct type.
  10. Ensure EGR system operates correctly.
  11. 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
PartPart numberQty
Restrictor plate717514681,9D JTD 16V/2,4D JTD 20V
Gasket551918831,9D JTD 16V/2,4D JTD 20V
Restrictor plate717514691,9D JTD 8V
Gasket467730821,9D JTD 8V

Data: Motorwise Workshop. Bulletin 12.

Brakes

2 documented faults — symptoms, causes and workshop fixes.

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

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

Data: Motorwise Workshop. Bulletin 6.

Squeaking noise from rear brakes

Affects All models.

Cause

Handbrake cable sticking due to internal damage/corrosion.

Repair

  1. Replace both handbrake cables.

Data: Motorwise Workshop. Bulletin 8.

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

  1. Fit modified front anti-roll bar.

Data: Motorwise Workshop. Bulletin 11.

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

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

Data: Motorwise Workshop. Bulletin 13.

Knocking/squeaking noise from rear suspension over uneven surfaces

Affects All models.

Cause

Rear trailing arm hub assembly bushes.

Repair

  1. Replace both rear trailing arm hub assembly bushes.

Data: Motorwise Workshop. Bulletin 14.

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

  1. Replace ASM transmission shift actuator accumulator.

Data: Motorwise Workshop. Bulletin 15.

Air conditioning & heating

1 documented fault — 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

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

Data: Motorwise Workshop. Bulletin 1.

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

  1. Clean and lubricate bonnet catch.

Data: Motorwise Workshop. Bulletin 4.

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

  1. Check front suspension upper arm bushes for excessive play.
  2. 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
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
Glow Plug
A heater that helps a diesel engine start from cold
ATC
Automatic temperature control — climate control that holds the temperature you set
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
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)
EGR Valve
The valve that meters exhaust gas back into the intake
Fault Memory
The list of stored trouble codes in a control module
Multi-Plugs
Multi-pin electrical connectors on a wiring harness
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
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 156 1.9 JTD 16V?

This guide contains 15 workshop bulletins for the Alfa Romeo 156 1.9 JTD 16V. Of these, six 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 156 1.9 JTD 16V 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 1.9 JTD 16V faults myself?

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

Related guides

Glossary term

See in the glossary →