Engine & fuel system
4 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 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
- Remove top engine cover.
- Fit vibration dampers to fuel injector pipes: 1.9D JTDM/JTD 16V 2.4D JTD 20V.
Parts2 parts
| Part | Part number | Qty |
|---|---|---|
| Vibration damper | 55214403 | 1,9D JTDM/JTD 16V |
| Vibration damper | 55214403 | 2,4D JTD 20V |
Data: Motorwise Workshop. Bulletin 9.
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.
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.
- 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
- 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
- TC
- Turbocharger — the exhaust-driven compressor that boosts engine power
- AC/Heater
- The heating and air-conditioning system
- 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)
- 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
- Bushes
- Rubber mountings that let a suspension or body joint move without metal-to-metal contact
Frequently asked questions
What are the common faults with the Alfa Romeo Crosswagon 1.9 JTD 16V 4x4?
This guide contains nine workshop bulletins for the Alfa Romeo Crosswagon 1.9 JTD 16V 4x4. Of these, four concern the engine and fuel system and two the brakes. Symptoms, causes, repair steps and part numbers are shown where supplied.
Does every Alfa Romeo Crosswagon 1.9 JTD 16V 4x4 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 Crosswagon 1.9 JTD 16V 4x4 faults myself?
Many of them. The documented symptoms can be seen, heard or felt during a test drive.