Alfa Romeo1997–2001

156 1.9 JTD: Common faults & known problems

Common faults & known problems

19 known faults documented in workshop bulletins. Of these, seven 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

7 documented faults — symptoms, causes and workshop fixes.

Poor driveability

Overview

Affects: All models, 1997-00.
Parts: 1 part

Symptoms

Hesitation/cutting out on acceleration.

Cause

Fuel lift pump impeller fouling casing, causing pressure fluctuations.

Repair

Check fuel pressure through 10 cycles by switching ignition ON and OFF every 10 seconds.
If pressure drops below 1.5 bar or rises above 2.0 bar, replace fuel pump.

Parts1 part

Parts listed in the bulletin
Part	Part number	Qty
Fuel pump	60664014	1

Data: Motorwise Workshop. Bulletin 1.

Immediate driving after starting with ambient air temperature below 0°C causes engine malfunction indicator lamp (MIL) to illuminate

Affects All models.

Cause

Failure of engine to reach operating temperature within parameter set by engine control module (ECM).

Repair

Start engine, allow to idle for 30 - 45 seconds before driving.

Data: Motorwise Workshop. Bulletin 4.

Engine malfunction indicator lamp (MIL) illuminated

Overview

Affects: All models, →01/01.

Symptoms

Random/single misfire.

Cause

Intermittent connection at multi-plug between accelerator pedal position (APP) sensor and engine control module (ECM).

Repair

Check for diagnostic trouble codes and delete as necessary.
Remove multi-plug and join wires permanently by soldering.

Data: Motorwise Workshop. Bulletin 6.

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 9.

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 11.

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 14.

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 16.

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 5.

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 10.

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 13.

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 15.

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 18.

Steering

1 documented fault — symptoms, causes and workshop fixes.

Buzzing noise from power steering high-pressure pipe

Overview

Affects: All models →1999.
Parts: 2 parts

Cause

Faulty retaining bolt/valve on power steering.

Repair

Replace retaining bolt/valve with modified version.
Bleed power steering system.

Parts2 parts

Parts listed in the bulletin
Part	Part number	Qty
Retaining bolt/valve	60807575	1
Seal	10282460	2

Data: Motorwise Workshop. Bulletin 2.

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 19.

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

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

Data: Motorwise Workshop. Bulletin 3.

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 7.

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 12.

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 8.

Glossary

Technical terms used in this guide.

ECM: Engine control module — the electronic unit that manages the engine
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
AC: Air conditioning — the system that cools the cabin
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
Accelerator Pedal Position: The sensor that tells the engine control module how far the accelerator is pressed
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
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
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
Evaporator: The air-conditioning heat exchanger in the dashboard that cools the cabin air
Lower Arm: A suspension link that locates the wheel at the bottom of the hub
Misfire: One or more cylinders not firing correctly — the engine runs roughly or loses power
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?

This guide contains 19 workshop bulletins for the Alfa Romeo 156 1.9 JTD. Of these, seven 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 1.9 JTD 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 faults myself?

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