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2004 Alfa Romeo 156

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By Research the Car 5 min read

The 2004 Alfa Romeo 156 is a stylish and sporty Italian compact executive car known for its sharp handling and distinctive design. While it offers a thrilling driving experience, it’s also known for being somewhat temperamental and requiring diligent maintenance. Engine options for the 2004 model year include the 1.6L Twin Spark (120 hp, 107 lb-ft), 1.8L Twin Spark (140 hp, 123 lb-ft), 2.0L Twin Spark (150 hp, 137 lb-ft), 2.0L JTS (165 hp, 151 lb-ft), 2.5L V6 (192 hp, 165 lb-ft), and the 1.9L JTD diesel (115 hp, 203 lb-ft) and 2.4 JTD diesel (136 hp, 224 lb-ft). Transmission options included a 5-speed manual, a 6-speed manual (available on the 2.0 JTS, 2.5 V6 and diesel engines), and a 4-speed automatic (Selespeed). Owners often praise the 156 for its engaging driving dynamics and iconic Italian styling. Common complaints include a reputation for electrical gremlins, suspension wear, and relatively high maintenance costs.

Engine

1.6L Twin Spark

  • Variator Failure
    • Description/Symptoms: A rattling noise, particularly on startup, indicates a failing variable valve timing (VVT) variator. This affects engine performance and fuel economy.
    • Solution: Replacement of the VVT variator.
    • Estimated Cost to Fix: $200 - $400+
    • Recalls: None Found

1.8L Twin Spark

  • Variator Failure
    • Description/Symptoms: A rattling noise, particularly on startup, indicates a failing variable valve timing (VVT) variator. This affects engine performance and fuel economy.
    • Solution: Replacement of the VVT variator.
    • Estimated Cost to Fix: $200 - $400+
    • Recalls: None Found

2.0L Twin Spark

  • Variator Failure
    • Description/Symptoms: A rattling noise, particularly on startup, indicates a failing variable valve timing (VVT) variator. This affects engine performance and fuel economy.
    • Solution: Replacement of the VVT variator.
    • Estimated Cost to Fix: $200 - $400+
    • Recalls: None Found

2.0L JTS

  • Direct Injection Issues
    • Description/Symptoms: The JTS (Jet Thrust Stoichiometric) engine, with its direct injection system, can suffer from carbon buildup on the intake valves. This can cause rough running, misfires, and reduced power.
    • Solution: Manual cleaning of the intake valves or walnut blasting to remove carbon deposits. A revised intake manifold design helps alleviate this issue, although it will not prevent it.
    • Estimated Cost to Fix: $300 - $600+
    • Recalls: None Found
  • Variator Failure
    • Description/Symptoms: A rattling noise, particularly on startup, indicates a failing variable valve timing (VVT) variator. This affects engine performance and fuel economy.
    • Solution: Replacement of the VVT variator.
    • Estimated Cost to Fix: $200 - $400+
    • Recalls: None Found

2.5L V6

  • Timing Belt Failure
    • Description/Symptoms: The Alfa Romeo V6 engine is an interference engine. This means if the timing belt fails it causes extensive damage. The timing belt and water pump should be replaced together according to a rigid schedule.
    • Solution: Replacing the timing belt and water pump. Extensive engine repairs are required if the timing belt breaks.
    • Estimated Cost to Fix: $600 - $1200+ (belt and pump) or significantly more if the engine is damaged.
    • Recalls: None Found
  • Oil Leaks
    • Description/Symptoms: Oil leaks are common, particularly from the valve cover gaskets, the front crankshaft seal, and the rear main seal.
    • Solution: Replacing the leaking gaskets and seals.
    • Estimated Cost to Fix: $100 - $400+ per leak depending on the location.
    • Recalls: None Found

1.9L JTD/2.4 JTD Diesel

  • MAF (Mass Air Flow) Sensor Failure
    • Description/Symptoms: Reduced power, poor fuel economy, and potential stalling can result from a faulty MAF sensor.
    • Solution: Replacement of the MAF sensor.
    • Estimated Cost to Fix: $100 - $300
    • Recalls: None Found
  • EGR Valve Problems
    • Description/Symptoms: The EGR (Exhaust Gas Recirculation) valve can become clogged with carbon deposits, leading to rough idling, poor performance, and engine warning lights.
    • Solution: Cleaning or replacing the EGR valve.
    • Estimated Cost to Fix: $150 - $400
    • Recalls: None Found

Transmission

Selespeed

  • Pump Failure
    • Description/Symptoms: The Selespeed automated manual transmission utilizes a hydraulic pump to actuate gear changes. The pump can fail, leading to difficulty shifting, complete transmission failure, and warning lights on the dashboard.
    • Solution: Replacement of the Selespeed pump.
    • Estimated Cost to Fix: $500 - $1000+
    • Recalls: None Found
  • Actuator Problems
    • Description/Symptoms: The Selespeed actuator, which controls gear selection, can develop problems with its sensors or hydraulic components. This can cause jerky shifting, missed shifts, and error messages.
    • Solution: Actuator repair or replacement.
    • Estimated Cost to Fix: $400 - $800+
    • Recalls: None Found

Suspension

  • Front Upper Wishbone Wear
    • Description/Symptoms: The front upper wishbones are a known weak point. Worn ball joints lead to knocking noises, particularly over bumps, and vague steering.
    • Solution: Replacement of the upper wishbones (often sold as a complete assembly).
    • Estimated Cost to Fix: $200 - $400+ per side
    • Recalls: None Found
  • Rear Suspension Bushing Wear
    • Description/Symptoms: The rear suspension bushings can wear, causing vague handling and knocking noises from the rear of the car.
    • Solution: Replacement of worn bushings.
    • Estimated Cost to Fix: $200 - $500+ depending on how many bushings need replacing
    • Recalls: None Found

Electrical

  • Dashboard Warning Lights
    • Description/Symptoms: The Alfa 156 can suffer from various electrical issues that trigger dashboard warning lights, often without a clear cause. These can include ABS, airbag, and engine management lights.
    • Solution: Diagnosis with a professional-grade diagnostic tool to pinpoint the specific fault. This can range from sensor replacement to wiring repairs.
    • Estimated Cost to Fix: $50 - $500+ depending on the issue.
    • Recalls: None Found
  • Window Regulator Failure
    • Description/Symptoms: Power windows may fail to operate due to faulty window regulators.
    • Solution: Replacement of the window regulator.
    • Estimated Cost to Fix: $200 - $400+ per window
    • Recalls: None Found

Exterior

  • Rust
    • Description/Symptoms: Rust can develop, especially in areas prone to moisture and road salt exposure, such as wheel arches and underbody.
    • Solution: Rust repair or panel replacement.
    • Estimated Cost to Fix: $200 - $2000+ depending on the severity and location.
    • Recalls: None Found

Interior

  • Dashboard Cracking
    • Description/Symptoms: The dashboard can be prone to cracking, particularly in hot climates.
    • Solution: Dashboard repair or replacement.
    • Estimated Cost to Fix: $100 - $1000+ depending on the repair method.
    • Recalls: None Found

Summary

The 2004 Alfa Romeo 156 is a rewarding but demanding car to own. The most common issues range from relatively minor electrical gremlins and suspension wear to more significant engine problems, especially with the VVT variator and Selespeed transmission. Rust can also be a concern, depending on the car’s history and location. Repair costs can vary widely, but it’s essential to factor in the potential for higher-than-average maintenance expenses when considering purchasing a 156. Potential buyers should thoroughly inspect the car’s service history and have it inspected by a mechanic familiar with Alfa Romeos.

Alfa Romeo, 156
Alfa Romeo 156 2004
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