Faults and recalls.

Engine / equipment

1.0 / 1.2 PureTech (EB2) in the Peugeot 208/2008/308/3008/5008, Citroën C3/C4/C5 Aircross, DS 3, Opel Corsa/Crossland/Grandland

Period mentioned

2012 – approx. 2022

Symptoms

Oil pressure warning, hard brake pedal or reduced assistance, oil consumption, blue smoke, squeal at the front of the engine, turbo whistles or loses power.

Possible cause described

The timing belt runs in oil and degrades (especially with short trips and fuel dilution). Debris clogs the oil pump strainer, the brake vacuum pump filter, the turbo oil feed and the variable valve timing solenoids. Stellantis announced compensation for affected owners in 2025.

Check for the garage

Measure the belt through the oil filler opening with the manufacturer's tool. Confirm whether the vacuum pump campaign was done.

Cost cited in the source

Vacuum pump: €500–800; belt with oil system cleaning: considerably moreA rough figure from the original database, not an up-to-date quote.

Sources from the original database

Engine / equipment

1.6 HDi DV6 (Peugeot 207/308/3008/Partner, Citroën C3/C4/Berlingo; same engine as the Ford 1.6 TDCi)

Period mentioned

Approx. 2004–2015

Symptoms

Loud turbo whistle, power loss, blue or black smoke, oil that gets dirty very quickly. Before the failure, often a puffing or ticking from the cylinder head and an exhaust smell from an injector.

Possible cause described

The injector clamp bolts work loose, the gas leak forms carbon that gets into the oil and clogs the mesh filter in the banjo bolt feeding the turbo. The turbo is starved of oil. Replacing only the turbo does not fix it.

Check for the garage

Check injector bolt torque and carbon at their base, the turbo banjo bolt and the sump strainer.

Cost cited in the source

Turbo + full oil system cleaning: approx. €900–2,000 (estimate)A rough figure from the original database, not an up-to-date quote.

Sources from the original database

Engine / equipment

1.5 / 1.6 / 2.0 BlueHDi with AdBlue (Peugeot, Citroën, DS, Opel)

Period mentioned

Approx. 2014 onwards

Symptoms

Emission system fault message and a “starting impossible in X km” countdown, AdBlue/UREA warning and engine light.

Possible cause described

Failure of the AdBlue tank pump module (circuit board, pressure sensor or heater) or of the AdBlue injector. The engine does not stop while driving, but once the countdown reaches zero it will not restart.

Check for the garage

Diagnose with Diagbox or equivalent: AdBlue pressure, flow test and tank temperature.

Cost cited in the source

Complete module or tank: approx. €600–1,500 (estimate)A rough figure from the original database, not an up-to-date quote.

Sources from the original database

Engine / equipment

1.6 THP / VTi (EP6, PSA-BMW “Prince” engine): Peugeot 207/208/308/3008/5008/508/RCZ, Citroën C4/C5/C4 Picasso, DS 3/4/5

Period mentioned

Approx. 2007–2018

Symptoms

Metallic rattle for several seconds after a cold start; engine light for timing deviation.

Possible cause described

The chain stretches and the tensioner is soft. Later units have a revised chain and tensioner, which reduce but do not eliminate the fault.

Check for the garage

Listen to a cold start and check whether the chain was replaced with the revised parts.

Cost cited in the source

Approx. €800–1,500 (converted from dollars)A rough figure from the original database, not an up-to-date quote.

Sources from the original database

Engine / equipment

1.5 BlueHDi (DV5): Peugeot 208/2008/308/3008/5008/508/Rifter, Citroën C3/C4/C5 Aircross/Berlingo, Opel, DS, Fiat

Period mentioned

2017–2023

Symptoms

Rattle from the top of the engine, loss of power; in severe cases the chain breaks and the engine fails.

Possible cause described

The 7 mm chain linking the two camshafts wears prematurely, influenced by soot in the oil. Stellantis replaced it with an 8 mm chain in 2023 and opened an inspection campaign.

Check for the garage

Ask the dealer whether the car is in the campaign (free inspection and replacement if needed) and whether the 8 mm chain is fitted.

Cost cited in the source

€700–1,400 for the chain; €4,000–7,000 if it breaksA rough figure from the original database, not an up-to-date quote.

Sources from the original database

Engine / equipment

1.3 Multijet / 1.3 JTD / 1.3 CDTI (Fiat Panda, 500, Punto, Doblò; Opel Corsa, Astra, Meriva, Combo; Lancia Ypsilon and Musa; Alfa MiTo; Peugeot Bipper and Citroën Nemo)

Period mentioned

2003–2020

Symptoms

Chain rattle on cold starts; oil level rising and smelling of diesel; particulate filter warning; power loss from a dirty EGR or the turbo.

Possible cause described

Single-row timing chain that is very sensitive to oil quality and long intervals: it stretches and the tensioner loses pressure, with a risk of breaking. In town use the DPF cannot finish regenerating and diesel dilutes the oil, which speeds up chain and turbo wear.

Check for the garage

Listen to a cold start, check whether the oil is above maximum or smells of diesel, read the DPF status and check the oil change history.

Cost cited in the source

Chain kit: €150–300 in parts plus €600–1,200 labour; DPF cleaning: €200–400A rough figure from the original database, not an up-to-date quote.

Mileage cited in the database: 80,000–120,000 km. This is not a maintenance interval and does not predict a failure.

Sources from the original database

Engine / equipment

1.4 MultiAir (naturally aspirated and turbo) and the 0.9 TwinAir, which uses the same system: Fiat 500, Punto, Tipo, 500X; Alfa MiTo and Giulietta; Jeep Renegade and Compass; Abarth

Period mentioned

2009–2024

Symptoms

Hard or rough cold starts, hesitation, stalling and an engine light with P1523 (low oil pressure in the MultiAir system).

Possible cause described

The intake valves are operated by oil pressure through an electro-hydraulic block. Degraded oil, a low level or a dirty secondary filter starve the system of pressure, and over time the actuator fails internally.

Check for the garage

Change the oil and filter with the correct specification, inspect the MultiAir mesh filter and measure oil pressure before replacing the actuator.

Cost cited in the source

Oil change: the cheapest step and often enough; MultiAir actuator: approx. €650–1,400 (converted from dollars)A rough figure from the original database, not an up-to-date quote.

Sources from the original database

Engine / equipment

PSA 2.0 HDi (DW10) and 2.2 HDi (DW12), including the 2.0/2.2 JTD in the Fiat Ulysse and Scudo and the Lancia Phedra

Period mentioned

1998–2015

Symptoms

Particulate filter warning and power loss; rough idle from a dirty EGR; vibration and knocks when starting or in low gears (dual-mass flywheel); smoke or hesitation from injectors at high mileage.

Possible cause described

The engine itself is very robust, but the ancillaries are not: the DPF with Eolys additive clogs in town use, the EGR and its cooler fill with soot, the variable-geometry turbo sticks and the dual-mass flywheel wears. The 136 hp versions have more problems than the 138 to 163 hp ones.

Check for the garage

Read the DPF status and additive level, check the EGR and cooler, check the dual-mass flywheel at start-up and measure injector balance rates.

Cost cited in the source

Forced DPF regeneration: €100–150; new DPF: €800–1,500; rebuilt injector: €200–250A rough figure from the original database, not an up-to-date quote.

Mileage cited in the database: 120,000–180,000 km. This is not a maintenance interval and does not predict a failure.

Sources from the original database

Engine / equipment

1.9 JTD / Multijet (8 and 16 valves), 2.4 JTD and JTDm in Fiat, Alfa Romeo 147, 156, 159, GT and Brera, Lancia and the Opel 1.9 CDTI

Period mentioned

1997–2012

Symptoms

Power loss, rough idle and an engine light with “swirl actuator malfunction”; soot around the intake manifold; vibration and knocks in low gears (dual-mass flywheel).

Possible cause described

On the 16-valve 1.9 and 20-valve 2.4, the intake flaps seize with EGR soot and oil, and the control rod comes off as its plastic bushes wear. The EGR fouls in town use and the dual-mass flywheel wears between 80,000 and 150,000 km. The 8-valve 1.9 has no flaps.

Check for the garage

Check the rod and flap operation on top of the manifold, read actuator codes, inspect the EGR and listen to the flywheel when starting and stopping.

Cost cited in the source

Intake manifold: €400–900 in parts; EGR cleaning: €150–250A rough figure from the original database, not an up-to-date quote.

Mileage cited in the database: 80,000–150,000 km. This is not a maintenance interval and does not predict a failure.

Sources from the original database

Engine / equipment

FIRE 1.1, 1.2 and 1.4 petrol, 8 and 16 valves (Panda, Punto, 500, Doblò, Idea, Linea, Lancia Ypsilon and Musa)

Period mentioned

2000–2020

Symptoms

Coolant loss, white smoke or mayonnaise-like oil (head gasket); misfires and, if the ECU is damaged, the car will not start or cuts out.

Possible cause described

A very robust engine with three weak points: the head gasket, which fails mostly between 80,000 and 150,000 km if the cooling system is neglected; the timing belt, whose failure bends valves on the 1.1, all 16-valve engines and the 1.2 with VVT; and the ignition coils, which as they degrade can damage the ECU.

Check for the garage

Check the coolant level and oil filler cap, check when the belt was last changed (also by age) and test the coils before they fail.

Cost cited in the source

Ignition coil: €40–60; head gasket and belt: depends on the garageA rough figure from the original database, not an up-to-date quote.

Mileage cited in the database: 80,000–150,000 km. This is not a maintenance interval and does not predict a failure.

Sources from the original database

Engine / equipment

Only configurations, equipment and VINs included in the documented assignments.

Period mentioned

Bulletin-specific period and equipment stated in each assignment.

Symptoms

Bluetooth or USB failure; possible battery drain.

Possible cause described

The Blue&Me unit can cause Bluetooth/USB failures or battery drain.

Check for the garage

Verify Blue&Me equipment and diagnose the unit; HELLA describes reprogramming and memory repair, with proxy alignment when required.

Cost cited in the source

No verifiable estimate; request a diagnostic and repair quotation.A rough figure from the original database, not an up-to-date quote.

Sources from the original database

Engine / equipment

Only configurations, equipment and VINs included in the documented assignments.

Period mentioned

Repairer-sheet period/subversions stated in each assignment.

Symptoms

C0121 valve-relay code; verify diagnosis and installed ABS.

Possible cause described

ECU Repair Centre reports C0121 valve-relay faults in the Marea Kelsey-Hayes module; it does not specify the underlying internal component.

Check for the garage

Confirm module reference and diagnose C0121; check the circuit before sending the module to a specialist for evaluation/repair.

Cost cited in the source

No verifiable estimate; request a diagnostic and repair quotation.A rough figure from the original database, not an up-to-date quote.

Sources from the original database

Engine / equipment

Getrag M32 six-speed manual: Opel Astra H and J, Insignia A, Zafira B and C, Vectra C, Meriva B, Cascada, Corsa OPC and some Fiats with the T-Jet engine

Period mentioned

2004–2019

Symptoms

A whine that rises with speed, mainly in 5th and 6th (also in 1st and 2nd), a loose gear lever that moves on and off the throttle and, when advanced, gears jumping out. Left unrepaired, the bearing can break through the casing.

Possible cause described

The bearings wear, mainly the shaft bearing next to 6th gear: the rollers develop play and the shaft moves under load, which reaches the lever. A specialist blames incorrect factory shimming. Second-generation boxes with the revised end case fail far less, according to an Australian repairer.

Check for the garage

In a garage test: confirm whether the noise depends on road speed (wheel bearing, tyre) or the gear engaged (gearbox), and whether the lever moves under load. Check the oil for metal debris. Repair early: replacing all bearings and fitting the revised end case costs far less than a new gearbox.

Cost cited in the source

One owner replaced only the main bearing for about £47 in parts versus about £1,000 for a rebuilt gearbox; another quotes about €600 at a specialist.A rough figure from the original database, not an up-to-date quote.

Sources from the original database

Engine / equipment

Dualogic robotised manual gearbox in the Fiat 500, Panda, Grande Punto / Punto Evo, Idea and Qubo, and Lancia Ypsilon and Musa

Period mentioned

2003–2020

Symptoms

The car drops into neutral when braking or driving with a beep and “Check gearbox”, will not engage gears or is slow to engage reverse, slow and hesitant shifts, oil under the actuator and sometimes no start because it cannot select neutral. The pump's whirr is no longer heard when opening the door.

Possible cause described

An electric pump and an electro-hydraulic actuator operate the clutch and gears. The pump motor, the actuator piston seals (hydraulic fluid leaks) and the solenoid valves fail, and clutch wear also leads to the car sticking in neutral. A specialist warns that the same symptoms can come from pressure loss, the pump, the actuator or the wiring.

Check for the garage

Check the battery (with a low charge the pump may not run) and the hydraulic fluid reservoir level, look for leaks under the actuator and, at a garage, read codes and measure pressure and clutch wear before replacing the whole actuator. After any repair the system must be relearned.

Cost cited in the source

According to forum owners: a complete hydraulic actuator costs over £1,000 in parts, and about €3,500 if the dealer replaces the whole “robot”. Many faults are fixed with a clutch, pump or actuator repair.A rough figure from the original database, not an up-to-date quote.

Sources from the original database

Engine / equipment

Fiat 500X (2016–2020), Jeep Renegade (2015–2020) and Jeep Compass (2017–2018) built without a drain hole in the silencer

Period mentioned

2015–2020

Symptoms

Below freezing the starter turns but the engine does not start; on days without frost it starts fine. More likely after short trips.

Possible cause described

Condensation water collects in the rear silencer and freezes, blocking the exhaust. FCA bulletin 09-004-20 (also valid in Europe) says to drill a 3 mm drain hole in the silencer.

Check for the garage

Ask the garage about bulletin 09-004-20 and whether the silencer already has the drain hole; until then, avoid leaving the car outside in frost right after a very short trip.

Cost cited in the source

Short garage job: drilling a drain hole; ask for a quote.A rough figure from the original database, not an up-to-date quote.

Sources from the original database