Engine & fuel system
5 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
- Check date code.
- If date code is not between 18/03/2004 and 21/04/2004, glow plug control module is OK.
- If date code is between 18/03/2004 and 21/04/2004 inclusive, replace glow plug control module using part listed.
Parts
| Part | Part number | Qty |
|---|---|---|
| Glow plug control module | 55193073 | 1 |
Data: Motorwise Workshop. Bulletin 2.
Poor starting when engine is hot
Cause
Engine control module (ECM) software mapping fault.
Repair
- Use diagnostic equipment to re-program ECM with upgraded software.
Parts1 part
| Part | Part number | Qty |
|---|---|---|
| Upgraded software | 1806563000 | 1 |
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
- Inspect turbocharger (TC) for damage, replace if necessary.
- Check and clean filter inside oil supply pipe banjo bolt.
Data: Motorwise Workshop. Bulletin 7.
Engine malfunction indicator lamp (MIL) illuminated
Symptoms
Trouble code stored: P1604.
Cause
Engine control module (ECM) software fault.
Repair
- Re-program ECM with modified software.
Data: Motorwise Workshop. Bulletin 9.
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
| 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 11.
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
- Remove and clean rear brake pads.
- Clean brake caliper carrier and lubricate.
Data: Motorwise Workshop. Bulletin 6.
Squeaking noise from rear brakes
Cause
Handbrake cable sticking due to internal damage/corrosion.
Repair
- 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
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 12.
Knocking/squeaking noise from rear suspension over uneven surfaces
Cause
Rear trailing arm hub assembly bushes.
Repair
- Replace both rear trailing arm hub assembly bushes.
Data: Motorwise Workshop. Bulletin 13.
Clutch & gearbox
1 documented fault — symptoms, causes and workshop fixes.
Occasional loss of drive
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 14.
Air conditioning & heating
1 documented fault — symptoms, causes and workshop fixes.
Outlet air distribution/temperature does not correspond to setting
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.
Body & trim
1 documented fault — symptoms, causes and workshop fixes.
Bonnet not opening or closing correctly
Cause
Bonnet catch seized.
Repair
- 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
- 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.
- 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
- 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
- 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 2.4 JTD 20V?
This guide contains 14 workshop bulletins for the Alfa Romeo 156 2.4 JTD 20V. 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 156 2.4 JTD 20V 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 2.4 JTD 20V faults myself?
Many of them. The documented symptoms can be seen, heard or felt during a test drive.