Alfa Romeo2004–2010

GT 1.9 JTDM 16V: Common faults & known problems

Common faults & known problems

15 known faults documented in workshop bulletins. Of these, six concern the engine and fuel system and three the electrical and ignition. Symptoms, causes, repair steps and part numbers are shown where supplied.

Technical specifications

Engine & fuel system

6 documented faults — symptoms, causes and workshop fixes.

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

  1. Remove top engine cover.
  2. Fit vibration dampers to fuel injector pipes: 1.9D JTDM/JTD 16V 2.4D JTD 20V.
Parts2 parts
Parts listed in the bulletin
PartPart numberQty
Vibration damper552144031,9D JTDM/JTD 16V
Vibration damper552144032,4D JTD 20V

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

  1. Check operation of thermostat.
  2. Check engine oil level correct.
  3. Check for contamination of fuel.
  4. Check fuel filter.
  5. Check whole intake system for leaks.
  6. Check mass air flow (MAF) sensor.
  7. Check for oil in intake system.
  8. Check fuel injectors for leaks.
  9. Check fuel injectors for correct type.
  10. Ensure EGR system operates correctly.
  11. 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
PartPart numberQty
Restrictor plate717514681,9D JTD 16V/2,4D JTD 20V
Gasket551918831,9D JTD 16V/2,4D JTD 20V
Restrictor plate717514691,9D JTD 8V
Gasket467730821,9D JTD 8V

Data: Motorwise Workshop. Bulletin 2.

Poor engine performance

Overview

Affects
All models.
Remedy
Fit new part
Parts
1 part

Symptoms

Whistling noise from engine/turbocharger (TC).

Cause

Turbocharger (TC) intercooler hose chafes against engine earth lead stud.

Repair

  1. Reposition engine earth lead and stud to adjacent bolt hole in engine mounting bracket.
  2. Fit new turbocharger (TC) to intercooler hose.
Parts1 part
Parts listed in the bulletin
PartPart numberQty
Intercooler hose517094701

Data: Motorwise Workshop. Bulletin 6.

Engine malfunction indicator lamp (MIL) illuminated

Overview

Affects
All models with Diesel engines.
Fault codes
P0237P0238P2562P2563

Symptoms

Lack of power. Possible trouble codes stored: P0237, P0238, P2562, P2563. Whistling noise from engine. White smoke coming from exhaust.

Cause

Turbocharger (TC) control pressure sensor faulty.

Internal failure of turbocharger (TC).

Repair

  1. Carry out electrical, mechanical and component tests (as applicable) to eliminate any other possible cause(s).
  2. If no fault(s) found: Replace turbocharger (TC) and turbocharger (TC) control pressure sensor.

Data: Motorwise Workshop. Bulletin 12.

Engine malfunction indicator lamp (MIL) illuminated

Affects All models with 1.9 Diesel engine.

Symptoms

Lack of power. Trouble codes related to intake system stored in fault memory.

Cause

Exhaust gas recirculation (EGR) valve stuck open/closed.

Repair

  1. Check operation of EGR valve. Replace components as necessary.

Data: Motorwise Workshop. Bulletin 13.

Moaning noise from engine bay at 1400-2100rpm

Overview

Affects
All models, →03/06.
Remedy
Fit modified part
Parts
3 parts

Cause

Resonance from fuel pipe located between fuel filter and high-pressure fuel pump.

Repair

  1. Renew fuel filter.
  2. Fit modified fuel pipe.
Parts3 parts
Parts listed in the bulletin
PartPart numberQty
Fuel pipe505054921
Fuel filter505054951
Hose clip467735761

Data: Motorwise Workshop. Bulletin 14.

Electrical & ignition

3 documented faults — symptoms, causes and workshop fixes.

Automatic window partial opening function not working correctly

Affects All models, VIN →5014726.

Cause

Electric window control module software fault.

Repair

  1. Replace electric window control module(s) as required.
Parts8 parts
Parts listed in the bulletin
PartPart numberQty
Electric window control module, left front - without retractable door mirrors (LHD)505105101
Electric window control module, left front - with retractable door mirrors (LHD)505105111
Electric window control module, right front - without retractable door mirrors (LHD)505105141
Electric window control module, right front - with retractable door mirrors (LHD)505105151
Electric window control module, right front - without retractable door mirrors (RHD)505105121
Electric window control module, right front - with retractable door mirrors (RHD)505105131
Electric window control module, left front - without retractable door mirrors (RHD)505105161
Electric window control module, left front - with retractable door mirrors (RHD)505105171

Data: Motorwise Workshop. Bulletin 5.

Automatic window partial opening function not working correctly

Affects All models, →03/08.

Cause

Electric window control module software fault.

Repair

  1. Replace electric window control module(s) as required.
Parts1 part
Parts listed in the bulletin
PartPart numberQty
Electric window control module505127172

Data: Motorwise Workshop. Bulletin 8.

Irregular operation of electric windows

Overview

Affects
All models, VIN 5260347-5262208.
Parts
2 parts

Cause

Driver's electric window switch faulty.

Repair

  1. Inspect production date code on driver's electric window switch.
  2. If the date code is 297, renew driver's electric window switch.
Parts2 parts
Parts listed in the bulletin
PartPart numberQty
Electric window switch, driver's door - LHD1560717381
Electric window switch, driver's door - RHD1560717391

Data: Motorwise Workshop. Bulletin 9.

Brakes

1 documented fault — symptoms, causes and workshop fixes.

Whistling noise from front brakes when brakes applied

Affects All models except 3.2.Fit modified part

Cause

Unsatisfactory design of front brake pads.

Repair

  1. Fit modified front brake pads.
Parts1 part
Parts listed in the bulletin
PartPart numberQty
Front brake pad kit773622291

Data: Motorwise Workshop. Bulletin 15.

Suspension & drivetrain

2 documented faults — symptoms, causes and workshop fixes.

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

  1. Mark position of rear suspension lower arm inner bolt.
  2. Fit new rear suspension lower arms.
  3. Realign marks and check rear wheel alignment.

Data: Motorwise Workshop. Bulletin 3.

Noise from front suspension over uneven surfaces

Affects All models.

Cause

Front suspension upper arm making contact with wheel arch lining.

Repair

  1. Modify front wheel arch lining by cutting off section where contact has occurred.

Data: Motorwise Workshop. Bulletin 4.

Clutch & gearbox

1 documented fault — symptoms, causes and workshop fixes.

Irregular operation of AC compressor clutch

Overview

Affects
All models, →06/04.
Remedy
Software update

Cause

Engine control module (ECM) software fault.

Repair

  1. Carry out electrical, mechanical and component tests (as applicable) to eliminate any other possible cause(s).
  2. If no fault(s) found: Re-program ECM with upgraded software.

Data: Motorwise Workshop. Bulletin 7.

Air conditioning & heating

1 documented fault — symptoms, causes and workshop fixes.

Engine malfunction indicator lamp (MIL) illuminated

Intake manifold air control actuator faulty. Fix: fit a new part.

Overview

Affects
All models with 1.9 Diesel engine (engine No. →4689071).
Fault codes
P2004P2013
Remedy
Fit new part

Symptoms

Trouble codes stored: P2004, P2013

Repair steps

  1. Erase trouble codes from ECM fault memory.
  2. Initialise intake manifold air control actuator as follows: Switch ignition ON. Switch ignition OFF. Wait 15 seconds.
  3. Repeat above procedure ten times.
  4. Check for trouble codes.
  5. If trouble codes P2004 and/or P2013 present, fit new intake manifold air control actuator.

Parts

Parts listed in the bulletin
PartPart numberQty
Intake manifold air control actuator5552051271

Data: Motorwise Workshop. Bulletin 11.

Other

1 documented fault — symptoms, causes and workshop fixes.

Metallic noise from fascia over uneven road

Affects All models, →02/05.

Symptoms

Rattling noise from audio unit area.

Cause

Excessive clearance between audio unit and surrounding.

Repair

  1. Apply felt tape to audio unit.

Data: Motorwise Workshop. Bulletin 10.

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
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
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
Actuator
A motor or solenoid that moves a mechanical part on command
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
Intake Manifold
The housing that distributes air into the cylinders
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
Earth
An electrical ground connection back to the battery or body
Initialise
A workshop procedure that teaches a new module or system its starting values
Intercooler Hose
The pipe that carries pressurised air between the turbocharger, intercooler and engine
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 GT 1.9 JTDM 16V?

This guide contains 15 workshop bulletins for the Alfa Romeo GT 1.9 JTDM 16V. Of these, six concern the engine and fuel system and three the electrical and ignition. Symptoms, causes, repair steps and part numbers are shown where supplied.

Does every Alfa Romeo GT 1.9 JTDM 16V 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 GT 1.9 JTDM 16V faults myself?

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

Related guides

Glossary term

See in the glossary →