Engine & fuel system
2 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 00089965-00092639.
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 1.
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 5.
Brakes
1 documented fault — symptoms, causes and workshop fixes.
Squeaking noise from rear brakes
Cause
Handbrake cable sticking due to internal damage/corrosion.
Repair
- Replace both handbrake cables.
Data: Motorwise Workshop. Bulletin 4.
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 2.
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 3.
Glossary
Technical terms used in this guide.
- 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
- MAF
- Mass air flow — a sensor that measures how much air the engine is breathing
- 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
- 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 20V?
This guide contains five workshop bulletins for the Alfa Romeo 166 2.4 JTD 20V. Of these, two concern 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 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 166 2.4 JTD 20V faults myself?
Many of them. The documented symptoms can be seen, heard or felt during a test drive.