Alfa Romeo2002–2007

166 2.4 JTD: Common faults & known problems

Common faults & known problems

4 known faults documented in workshop bulletins. Of these, one concerns the engine and fuel system and one the brakes. Symptoms, causes, repair steps and part numbers are shown where supplied.

Technical specifications

Engine & fuel system

1 documented fault — symptoms, causes and workshop fixes.

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 4.

Brakes

1 documented fault — 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 3.

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.

Glossary

Technical terms used in this guide.

EGR: Exhaust gas recirculation — feeds some exhaust gas back into the intake to cut emissions
MAF: Mass air flow — a sensor that measures how much air the engine is breathing
EGR Valve: The valve that meters exhaust gas back into the intake
Bushes: Rubber mountings that let a suspension or body joint move without metal-to-metal contact
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 166 2.4 JTD?

This guide contains four workshop bulletins for the Alfa Romeo 166 2.4 JTD. Of these, one concerns the engine and fuel system and one the brakes. Symptoms, causes, repair steps and part numbers are shown where supplied.

Does every Alfa Romeo 166 2.4 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 166 2.4 JTD faults myself?

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