Recalls: Alfa Romeo 147
Overview
Manufacturers, or importers, issue recalls for defects or faults which have the potential to cause injury. Generally, manufacturers will inform the original buyers if their vehicle is subject to a recall and of the steps required to remedy the defect or fault. Please note that the recalls below (if any) are for Australian-delivered vehicles only. Furthermore, the number of recalls should not be taken as an indication of a model’s reliability or its safety more generally.
Recalls: Alfa Romeo 147
Alfa Romeo 147: potential fuel leak
In April 2005, a recall was issued for Alfa Romeo 147 vehicles due to a possible crease or crack of the fuel vapour hose which occurred during production as the vapour hose was fitted to the fuel tank. As a result, fuel odour or leakage could occur when the tank was filled to its maximum (PRA 2005/7702).
Alfa Romeo 147 1.9 JTD: interference between fuel supply pipe and filter mounting
In July 2007, a recall was issued for Alfa Romeo 147 vehicles fitted with the 1.9-litre turbo-diesel engine due to a possible interference between the fuel supply pipe – from the diesel filter to the high pressure pump – and the fuel filter mounting (PRA 2007/9415,PRA 2007/9384).
Alfa Romeo 147: tyre sidewall could crack
In April 2010, a recall was issued for Alfa Romeo 147 vehicles fitted with Pirelli 215/40 ZR18 89W (MO) tyres due to a defect which could cause the sidewall of the tyre to crack and cause the tyre to lose pressure (PRA 2010/11591).
Problems and faults: Alfa Romeo 147
Overview
This section identifies potential problems, causes and fixes based on the experiences of owners and repairers, online sources and technical service bulletins. This information is provided solely for reference purposes and AustralianCar.Reviews recommends that only properly qualified persons carry out repairs or modifications. Furthermore, the number of items below should not be taken as an indicator of a model’s reliability or the frequency with which they may occur.
To report a problem or fault to the AustralianCar.Reviews team, please use the Contact Us form. Note that AustralianCar.Reviews does not offer advice on automotive problems or disputes; such enquiries will not receive a reply. For vehicles purchased from dealers after 1 January 2011, please see our Australian Consumer Law fact sheet.
Alfa Romeo 147 Twin Spark: timing belt failure and change interval
For the 2.0 Twin Spark engine, the timing belts were susceptible to failing prematurely and causing serious engine damage. In November 2006, the change over interval was changed from every 72,000 miles to 36,000 miles/60,000 kilometres, or every three years (whichever comes first). It is also recommended that the water pump be changed at the same time since the impellers are made of plastic and may crack.
Alfa Romeo 147 Twin Spark: variable idle and clatter
- A fluctuating idle speed may be due to a malfunctioning idle actuator (which requires replacement), an air leak around the inlet manifold or the throttle cable may have been dislodged when cleaning the throttle body. For the latter, resetting the engine control unit (ECU) may be required to restore proper idle.
- A clattery or diesel-like idle on start up and reduced performance may be due to the variator – which regulates camshaft timing – failing.
Alfa Romeo 147 1.9 JTD: M32 transmission bearing failure
Symptoms of worn bearing
For Alfa Romeo 147 1.9 JTD vehicles, the bearing on top of the sixth gear in the M32 manual transmission is susceptible to wear and, eventually, failure. Symptoms of a worn bearing include –
- Gearstick movement: when disengaging the clutch in 1st gear and pulling away – while holding the gearstick – the gearstick may move back into your hand by around 10 to 20 mm (the greater the movement, the worse the bearing wear). After further wear, this movement may also occur when the transmission is in fifth or sixth gear;
- A whining noise in 1st, 2nd, 5th and 6th gear: a whining noise may be heard from the glovebox area when driving in 1st, 2nd, 5th and 6th gears. In particular, a whining noise may be heard when driving at highway speeds in sixth gear and the accelerator is pressed; and,
- A whining noise in all gears: a whining noise – which is proportional to vehicle speed – may be heard in all gears regardless of whether the clutch is engaged or disengaged.
Explanation of symptoms
The bearing which is susceptible to wear sits on top of the output shaft that is responsible for gears 1, 2, 5 and 6 – this is why these gears exhibit the symptoms described above. For these symptoms,
- It is wear of the bearing rollers which causes them to be loose and have excessive play (see video below; the HSV VXR also had the M32 transmission). This, in turn, causes movement in the gearstick since the gear linkage is connected to an internal selector, and bearing wear causes the shaft inside the gearbox to move up and down when power is applied. The shaft then moves the selector ring which feeds back to the gearstick; and,
- Whining noises are caused by pitted pinion bearings which may be due to metal fatigue. It is understood that M32 transmissions produced from 2010 to 2012 are more susceptible to pitted pinion bearings since General Motors replaced the Timken and SNK bearings with FAG and NGBC bearings.
Cause of bearing wear
The primary cause of bearing wear is inadequate lubrication and subsequent overheating – this may be attributed to:
- The design of the M32 transmission: while the original M32 transmission was introduced in 2004, a revised ‘Generation 2’ M32 transmission was introduced for the 2012.5 ‘model year’ (though some vehicles were not fitted with the revised transmission until 2013). The ‘Generation 2’ M32 transmission had:
- Revised end casings in which there was an oil feed to the output shaft end bearing that passed through the input shaft end bearing; and,
- Larger bearings (62 mm compared to 55 mm) with greater surface area.
- Oil overheating: if the gearbox oil overheats, it will no longer conform to its specifications and adequately lubricate the bearings; and,
- Inadequate servicing: oil deteriorates over time and needs to be replaced according to the scheduled service intervals.
Management and ‘clutch slip’ warning
When the driver becomes aware of the symptoms above, it is recommended that 5th and 6th gears are avoided and the 3rd and 4th gears are used instead since this transfers the engine’s torque to the other output shaft and takes the load off the worn bearing.
If the worn bearing is not replaced, the outer bearing race can start to spin and wear the casing. Eventually, this can punch a hole in the casing, the bearing may collapse, the rollers can release and cause damage to the gears – if this occurs, the entire transmission has to be replaced. Owners have described clutch slip as a warning that the bearing is about to collapse.
Repair options
In repairing the M32 transmission, the standard replacement option is to replace all six bearings – this includes the faulty ‘6th gear’ bearing, the 4th gear output shaft bearing, both input shafts and both pinion bearings. This requires removal of both input and output shafts/gears sets, and replacing the inner and outer races. Since this method does not address the lubrication deficiencies of the original M32 transmission, however, it is recommended that the ‘Generation 2’ casing with larger bearings be fitted. To install the ‘Generation 2’ casing, the entire gearbox has to be removed.
For further information about the M32 transmission, please see:
- Eco Torque UK: M32 Gearbox – uprated bearings and end casing;
- Tech 2 Guru: Vauxhall M32 six-speed manual transmission; and,
- WG Motor Works: M32 Gearbox.
Alfa Romeo 147 1.9 JTD: water pump seizure
For the 1.9-litre turbo-diesel engine, the water pump could seize due to failed bearings, causing the timing belt to stretch and snap. As such, it is recommended that the timing belt, tensioner, pulleys and water pump be replaced every 60,000 kilometres.
Alfa Romeo 147 1.9 JTD: EGR valve stuck
For the 1.9-litre turbo-diesel engine, the Exhaust Gas Recirculation (EGR) valve may stick open so that the air pressure provided by the turbocharger is bled off into the exhaust system – if this occurs, there will be a lack of low-end power and power delivery will noticeably increased beyond 3000 rpm when the amount of air the turbocharger can compress exceeds the amount of air that can be bled out of the inlet manifold.
A faulty mass air flow (MAF) sensor can also cause problems with power delivery, but generally causes a lack of top-end power rather than low-end power.
Alfa Romeo 147 1.9 JTD: other problems and faults
- If the engine produces smoke or the vehicle suddenly loses power, the secondary butterflies of the swirl actuator valve may have seized due to a build-up of soot. To fix, the inlet manifold requires changing – this requires the fuel pump and cam belt to be removed.
- For black smoke from the exhaust and a loss of power, the turbo-intercooler or intercooler-intake manifold hoses may have split, or the intercooler may have cracked. The resultant loss of air pressure causes the injected fuel not to be combusted, instead turning into black smoke.
- If there is a lack of power below 3000 rpm, the Variable Geometry Turbocharger (VGT) regulation valve may have a cracked vacuum hose such that the turbocharger is in a high revs position. Alternatively, the VGT regulation valve may be jammed inside, requiring the turbocharger to be disassembled for repairs.
- If the engine shuts down when driving or fails to start, the crankshaft rotation sensor or camshaft position sensor may have failed.
- If the engine temperature is between 50-60 degrees when driving (should be 80-90 degrees), the thermostat may be partially opened or opening too early, causing sub-optimal combustion and requiring replacement.
Front suspension: upper wishbone and anti-roll bar
A squeaking noise from behind the dashboard can indicate that the front upper wishbone requires replacement. However, a creaking noise may be due to a worn anti-roll bar that requires replacement.
Rear suspension
For the rear suspension, the rear hub bushes and rear radius arms should be checked for wear as these can cause uneven tyre wear (such as a saw-tooth pattern on the inner edge of the tyre) and excessive tyre noise.
Alfa Romeo 147: bonnet release mechanism
The bonnet release mechanism may accumulate debris and cause the primary latch to cease working – in other countries, there were reports of the bonnet flipping and hitting the windscreen as a result. Overseas recalls were issued which involved degreasing, cleaning and refitting the existing mechanism. Later 147s had a plastic catch instead of a steel one, though this did not completely fix the problem. Owners should shut the bonnet firmly and pull on the leading edge to ensure that it is shut securely; WD40 can also be used to clean the mechanism.
