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Discussion Starter #1
:rant:apologies in advance!:rant:

So I bought my 159 on 15th dec '10, so far its been back to the dealers to have the washer pump replaced and the wiper arm assembly under the scuttle panel repaired (took 2 trips as they didn't have the correct parts (Meridien Majestic Bournemouth btw)).

The weekend just gone nearly had me taking a match to the thing;

Saturday, everything fine apart from the new wiper that the dealer fitted doesn't clear anything in my line of vision, can live with that as I will fix myself.

Sunday, driving back to mine from the outlaws everything OK (<4miles). 20mins later set off to the mothers to be met with a 'Check Engine' & associated warning light along with *absolutely NO power*. I mean the car would not go over ~40mph, the turbo was showing <0.8 bar boost and was being overtaken by slugs!

I have done a lot of reading on this forum prior to registering so am aware of the DPF problems with these (and other modern diesels) so took the chance to cane the cr*p out of it in 2nd for about 10 miles on the dual carriageway. Nothing changed and did not notice the mpg dipping drastically (signalling a DFP regen?). Eventually got to the mothers and left the car for a few hours.

Fire it up to go home and guess what? Warning light still on but all power is back!

So Monday morning I installed FiatECUScan and used my old VAGCOM lead to take a look at the fault code. Cooling Fan warning was the only error logged so I cleared that and then the warning light went out. I took the opportunity to do a forced regen on the car and this completed successfully.

So, feeling happier, I took the car to my chiropractor appointment and then the *new* wiper arm fell off whilst doing 60ish in the pi$$ing rain FFS!

I've since fixed that (nut wasnt tightened properly) and am currently waiting for the next chapter in my Alfa Owner story (I've had £100 $hitters that have had less problems than this car!! although i still love it for some reason)!
 

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Hi there,

Sounds firstly like the monkey who put your new wiper arm/blade on needs to cop the criticism here and not the car. After all a wiper arm can be fitted incorrectly to any vehicle by an incompetent.

Which model 159TI is your car? Is it a 1.9 or a 2.4?

I think you need to read up on the threads on here about remapping, EGR disabling and DPF removal. The EGR and DPF seem to be such a problem area for the diesel engines in so many cars (not just Alfas) and removal does seem to solve pretty much all of them.

Hope nothing else goes wrong in the meantime.

Oh an welcome to the forum! :D

J:)
 

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Discussion Starter #3
Thanks Jerry, (its a 1.9btw) yeah I have seen a few threads about the remap/DFP/EGR and will probably go down that route once the warranty is up.

Agree with what you are saying ref the wiper its just annoying that a lot of things happened at the same time. I'm also getting a few 'misfires' so have bunged some redex in to try and cure this, although I've also seen threads about this and it worringly seems to point towards injectors/manifold?
 

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What mileage is on the car?

Also, does it do lots of short journeys?

The symptoms you describe could easily be EGR related. This clogs up very easily and it also affects the inlet manifold that gets bunged up too.

Having the manifold removed and thoroughly cleaned along with the EGR and then having the EGR disabled should pretty much cure any of the misfires you have.

J:)
 

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Discussion Starter #5
Jerry, the mileage is relatively high (for the age) @ ~63500 miles, my drive consists of 15 minute commute twice a day with a 150mile+ motorway blast monday & friday.

I obviously don't know what style of driving the previous owner had but judging by the number of miles on the car I can only assume a lot of motorway driving.

'Having the manifold removed and thoroughly cleaned along with the EGR and then having the EGR disabled should pretty much cure any of the misfires you have.'

^^Would the dealer do this under warranty if I complained enough about it or would it be an independant job?
 

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Because of the non-standard nature of the work and also because it involves the removal of a part of the engine that is deemed to improve emissions, I very much doubt that a dealer could be seen to be removing or disabling EGRs or DPFs.

It would be an independent job for sure. I would trawl this site to find a specialist that could carry out the work properly and tie it all in with a nice ECU remap. Looking at the mileage of your car and going from plenty of posts on here that I have read it wouldn't surprise me if your EGR valve was in some way very clogged up or was on the blink. It either needs replacing or (better IMO) disabling.

Look at any posts on here by anyone who has had their EGR or DPF removed/disabled and not one has had any problems since. To me its a complete no brainer. The only downside being that it would invalidate your warranty.

By the way, do you have any more pics of your car. It looks stunning in your avatar.

J:)
 

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You should check if the EGR has ever been changed.... if not get them to put a new one on and see how it runs then, mines only done 50k and had EGR replaced a few times including fitting a faulty one which gave me your issue every couple of weeks for 6 months plus until they changed it again! Ive now had the DPF removal and EGR turned off and all is fine! My milage is very low in the week and thats probably what a proportion of my issues were about but the faulty EGR didnt help!
 

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Discussion Starter #8 (Edited)
Jerry, thanks for clearing that up, I will scale some of the pics correctly and get some up on this thread when I've got a few spare minutes.

John, would this be something a dealer would do as a matter of course for the issues I've been experiencing then or is it a pain in the **** for them so will try to fob me off with the old 'your driving style is incorrect' BS? 50K miles does not sound like a long enough lifespan, is there a common feeling on how long these should last?

On another note I have noticed that the laquer is peeling on all of my brake calipers and I remember seeing someone on here say that they got these replaced under warranty, chances??

Jerry, I've just uploaded some pics of the wagon (& my little pug!) into my profile gallery
 

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The 2 faults you mentioned sound to me like you had frozen screenwash and tried to operate the washers and your wipers were frozen and you tried to operate them. That wouldn't be the car's fault.
 

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Discussion Starter #10
@ stibbs you may be right ref the frozen washer bottle but i always stick roughly 75% screenwash to 25% water in the bottle as the 159 doesnt have heated washer jets. The wiper fell off after roughly 15 minutes of driving in heavy rain so they werent frozen to the window or anything like that.
 

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Discussion Starter #11 (Edited)
update on my 159. So after waiting 2 weeks to get the 159 into my local dealer to sort the wiper arm (3rd time lucky!), I now have a fully functioning, non bonnet scraping, windscreen clearing wiper!

Whilst the car was in I asked Rob in servicing (very nice chap) to take a look at the calipers (all 4 of them have serious laquer peel), to check out the issue with the car going into limp mode (did it again last friday), and to investigate a random misfire when on light throttle.

So they ran it through the diag and because i'd cleared the fault (in order to get home on a friday night) they could tell what the issue was.

Ref the missfire he mentioned there was a ECU software update that may have helped (my car was registered in june '08 and the ECU software is dated august '09) but I already have the latest so no joy.

So now I've got to wait for the limp mode to happen again and give them a bell when it does :-(

*EDIT* just checked and FES keeps logs - sweet! the ECU software is dated 30th March '09 not august as previously mentioned. I also have the error code which kicks off limp mode:

'P0480 - Cooling fans control 1
Cooling Fan 1 Control Circuit
The reason for this fault is that ECU has received very low signal from the sensor. The fault is present now. Take appropriate action to fix this sensor. Dashboard warning light was activated for this fault.'

Any ideas?
 

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sorry to slightly hijack your thread, but did you have to pay a diagnostic fee before they did any work? They are trying to sting me with this at the minute. Guess your work was under warranty?
 

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Discussion Starter #13 (Edited)
no mate, the car is still under warranty and didnt even mention a charge, all I had to do was sign the warranty jobsheet. TBH i think charging a customer to diagnose a fault with a car that is under warranty is completely unacceptable. Why not make it so the fuse box has an LCD display that shows error codes like some computer motherboards do? It would save plugging the car up and could be read by anyone?

I did see a thread ref the charges earlier. I've also seen it on the audi RS forums whereby a dealer will charge ~£75 just to tell you whats wrong with our car!

Is your car out of warranty?
 

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sorry to slightly hijack your thread, but did you have to pay a diagnostic fee before they did any work? They are trying to sting me with this at the minute. Guess your work was under warranty?
If you are having trouble, find a good indie.

Know a good one at J28 of the M1. Maybe a bit too far South for you?
 

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Still in full alfa warranty mate (bought dec). I am going to phone them up tomorrow and cancel the appointment. Then contact alfa uk. Junction 28 is no distance, but I will go dealer route first, cheers though.
 

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Discussion Starter #16
Ask them why they are charging you. The cars got a fault, its under warranty, they diagnose & fix for free in my opinion. I only bought mine in december too, its been back 3 times and they've not once charged me
 

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Discussion Starter #18
OK, so just spoke to the dealer and gave them the fault code, they are going to fit a new radiator cooling fan ECU. How many ECU's do these cars have???

Will update once fitted.
 

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Discussion Starter #19
guys, been doing a lot of searching & reading of similar threads to try and find out the cause of the dire mpg, lack of power & hesitation / misfire.

I now understand I'm never going to get VAG style mpg from the car but would like more than 33!

So far I can conclude that the issue could be
a) faulty / worn out EGR valve
b) split or loose turbo/intercooler pipe
c) knackered injectors / filthy inlet manifold

What do you guys reckon? this should be covered by warranty right? What should I be saying to my dealer to get them to investigate further than running it through their diag software, getting no fault codes and saying there's nothing wrong?
 

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I have a much lower mileage Ti and I'm getting 33 at best with a mix of all types of driving. It's not due for a service for a couple of months probably but will get it checked out properly again then (and NOT by a main dealer) If the indy spots anything unto wards, he has a good relationship with the actual dealer, so will get them to fix anything that should be covered.

last time the dealer ran a diagnostics etc they said it was all fine, no faults etc, even though the Engine light had come on at least three times and then cleared the next day.
I claim mileage back from my employer at 12p per mile and I reckon it costs at least 14/15p, so the 33mpg I'm getting is giving me serious grief. No obvious faults and have had a forced regen but makes no difference.
Guess we just don't believe Alfa's claimed figures.
 
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