Faults and recalls.

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

Campaign-specific production period; confirm by VIN.

Symptoms

The source describes the risk stated under cause; it does not document DTCs or additional advance symptoms.

Possible cause described

Insufficient rod lock-nut tightening can cause loss of steering.

Check for the garage

Confirm campaign 6452 VIN and perform the manufacturer correction.

Cost cited in the source

No verifiable estimate. Confirm campaign eligibility and free repair with the manufacturer by VIN.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

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

Bulletin-specific period and equipment stated in each assignment.

Symptoms

Airbag warning; stored high-value/open-circuit fault without a published numeric code.

Possible cause described

Vibration can loosen connectors and impair contact.

Check for the garage

A technician should check and secure airbag connectors/loom as directed by HELLA and clear faults after 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

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

Period mentioned

Campaign-specific production period; confirm by VIN.

Symptoms

The source describes the risk stated under cause; it does not document DTCs or additional advance symptoms.

Possible cause described

The steering-angle sensor may fail specification in ESP-equipped Thesis cars from the stated batch.

Check for the garage

Confirm VIN; check and replace the sensor as specified by campaign 4570.

Cost cited in the source

No verifiable estimate. Confirm campaign eligibility and free repair with the manufacturer by VIN.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

Bulletin-specific period and equipment stated in each assignment.

Symptoms

Warm air during the first few minutes after selecting cooling.

Possible cause described

A faulty control unit can delay regulation and keep delivering warm air after selecting cooling.

Check for the garage

With automatic climate control, check the unit; HELLA identifies the modified version as S40. If already fitted, investigate other causes.

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

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

3.6 V6 Pentastar: Jeep Grand Cherokee, Wrangler and Gladiator, Chrysler Grand Voyager and 300C, Lancia Thema and Fiat Freemont

Period mentioned

2011 onwards

Symptoms

Oil spots under the car, oil on the block below the housing (in the engine’s “V”), frequent top-ups and, in serious cases, a low oil-pressure warning; sometimes coolant leaks too.

Possible cause described

The plastic housing that holds the oil filter and cooler sits in the middle of the engine, exposed to heat: with heat cycles it warps and cracks. Overtightening the filter cap also damages it. Chrysler revised the design in 2014, but leaks still occur.

Check for the garage

Look for oil in the centre of the engine and under the car; do not overtighten the filter cap. The usual repair is replacing the whole assembly (aluminium versions exist), removing the intake manifolds, with new gaskets.

Cost cited in the source

No verified estimate; ask the garage for a quote.A rough figure from the original database, not an up-to-date quote.

Sources from the original database

Engine / equipment

2.8 CRD by VM Motori: Jeep Cherokee, Wrangler, Chrysler Voyager, Dodge Nitro and Lancia Voyager

Period mentioned

2001–2018

Symptoms

Hesitation, smoke and loss of power from the EGR or particulate filter; a failing turbo or intercooler; if the timing belt breaks, serious damage (interference engine).

Possible cause described

The block is considered robust: problems usually come from the ancillaries (turbo, intercooler and emissions equipment, especially the EGR valve). Owners point out that the timing belt is expensive and must be changed on time (about 160,000 km).

Check for the garage

Check when the belt was changed; read the EGR and filter codes; check the turbo and intercooler pipes.

Cost cited in the source

No verified estimate; ask the garage for a quote.A rough figure from the original database, not an up-to-date quote.

Sources from the original database

Engine / equipment

1.2 Hybrid 48 V: Peugeot 208 and 2008, Citroën C3, C3 Aircross, C4 and C4 X, DS 3, Opel Corsa, Frontera and Mokka, Jeep Avenger, Alfa Romeo Junior, Fiat 600 and Grande Panda, Lancia Ypsilon

Period mentioned

2023 onwards

Symptoms

Engine or electrical-fault warning light, a hot or burning smell under the bonnet and, in extreme cases, an engine-bay fire.

Possible cause described

There is too little clearance between the petrol particulate filter duct and the 48 V hybrid system’s guard (belt starter-generator): in humid conditions water can get in, an electric arc can form and it can overheat. Stellantis recalled about 700,000 cars worldwide (36 incidents, 12 with fire) and advises against pressure-washing the engine until the repair.

Check for the garage

Check the recall by VIN; do not pressure-wash the engine; with the warning or a burning smell, stop and park outdoors.

Cost cited in the source

Free under the recall.A rough figure from the original database, not an up-to-date quote.

Sources from the original database

Engine / equipment

VM Motori 3.0 V6 diesel (A630, “EcoDiesel”): Jeep Grand Cherokee and Gladiator, Chrysler 300C, Lancia Thema and Maserati Ghibli, Quattroporte and Levante

Period mentioned

2011 onwards

Symptoms

Coolant loss, white smoke or combustion in the intake manifold (cracked EGR cooler); deep metallic knock and the oil-pressure warning (bearings); on engines from 2020, low oil-pressure warnings or a failing high-pressure pump shedding metal.

Possible cause described

According to mechanics and owners, the EGR cooler cracks from thermal fatigue (Chrysler recalled it) and the crankshaft bearings can fail from lugging at low revs or carbon in the oil passages. On the third generation (from 2020) there was a recall for the Bosch CP4.2 fuel pump. Maserati uses the same VM engine in its diesels.

Check for the garage

Check the EGR-cooler and pump campaigns by VIN; watch the coolant and oil pressure; with knocking or the oil warning, stop. Avoid lugging the engine at very low revs under heavy load.

Cost cited in the source

No verified estimate; ask the garage for a quote.A rough figure from the original database, not an up-to-date quote.

Sources from the original database