Alfa Romeo 159 Problems Common Issues and Repair Costs
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Alfa Romeo 159 Problems: Common Issues and Repair Costs

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The Alfa Romeo 159, built between 2005 and 2011, is admired for its design, handling and road presence. It was offered with a range of petrol and diesel engines and is available in saloon and Sportwagon body styles. However, while it’s one of the best-looking cars in its class, it’s not without its faults. In this guide, we’ll cover the most common Alfa Romeo 159 problems and realistic UK repair costs, helping you understand what to expect before buying or owning one.

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1. Suspension and Wishbone Wear

Suspension issues are common on the 159, especially on heavier diesel variants. Components like wishbones and bushes are known to wear quickly.

Symptoms:

  • Knocking noise over bumps
  • Uneven tyre wear
  • Steering play or vibration

Causes:

  • Worn suspension arms
  • Bush deterioration
  • Ball joint fatigue

Repair costs:

  • Front wishbone: £150 to £250 per side
  • Full suspension kit fitted: £500 to £700
  • Wheel alignment: £60 to £100
  • Total: £150 to £700

2. DPF and EGR Issues (Diesel Engines)

Diesel 1.9 and 2.4 JTDm engines can suffer from clogged diesel particulate filters and EGR valve failures, particularly if mainly used for short journeys.

Symptoms:

  • Engine warning light
  • Poor acceleration
  • Smoke from exhaust

Causes:

  • Blocked DPF
  • Failing EGR valve
  • Faulty DPF sensors

Repair costs:

  • Forced DPF regen: £100 to £200
  • EGR valve replacement: £250 to £400
  • New DPF: £600 to £1,200
  • Total: £100 to £1,200

3. Cambelt Failure (Diesel Engines)

The 1.9 and 2.4 diesel engines are interference designs, meaning a snapped cambelt can cause serious internal damage.

Symptoms:

  • Sudden engine cut-off
  • No restart
  • Loud mechanical noise

Repair costs:

  • Cambelt and water pump: £400 to £600
  • Engine rebuild if failed: £1,200 to £2,000
  • Total: £400 to £2,000

4. Electrical Faults and Warning Lights

The 159’s electrical system is complex and prone to occasional glitches, especially in older or poorly maintained cars.

Symptoms:

  • Airbag or ABS lights
  • Central locking failure
  • Battery drain

Causes:

  • Poor earth wiring
  • Body control module issues
  • Flat or weak battery

Repair costs:

  • Battery replacement: £120 to £180
  • Wiring and earth check: £80 to £150
  • BCM replacement: £300 to £500
  • Total: £80 to £500

5. Gearbox and Clutch Wear

The 159 is known to develop clutch and gearbox issues, particularly in higher mileage diesels or cars used for towing.

Symptoms:

  • Stiff or jerky gear changes
  • Clutch judder
  • Noisy gearbox

Causes:

  • Worn clutch
  • Dual-mass flywheel wear
  • Gear selector mechanism failure

Repair costs:

  • Clutch replacement: £400 to £600
  • Dual-mass flywheel: £500 to £800
  • Manual gearbox rebuild: £800 to £1,200
  • Auto gearbox service: £250 to £400
  • Total: £400 to £1,200

6. Heater Matrix and Water Leaks

Water ingress and heater failures can be a problem, especially on Sportwagon models and early saloons.

Symptoms:

  • Damp carpets
  • No hot air from vents
  • Fogging windows

Causes:

  • Blocked scuttle drains
  • Leaking heater matrix
  • Failing door or boot seals

Repair costs:

  • Heater matrix: £350 to £500
  • Seal replacement: £100 to £250
  • Drain clearing: £80 to £120
  • Total: £80 to £500

7. Exhaust Flexi Joint Wear

Exhaust issues are common on the 159, particularly failed flexi joints or rattling heat shields.

Symptoms:

  • Metallic rattle
  • Exhaust blowing
  • Increased engine noise

Causes:

  • Cracked flexi pipe
  • Exhaust mounting failure
  • Rust on joints

Repair costs:

  • Flexi pipe section: £100 to £250
  • New mounts: £50 to £100
  • Replacement exhaust section: £300 to £500
  • Total: £100 to £500

Is the Alfa Romeo 159 Reliable?

The 159 can be a reliable and enjoyable car when properly looked after. Diesel models require strict servicing schedules, especially around the cambelt, EGR, and DPF. Suspension and electrical wear are the most common issues in older examples. A good service history and regular maintenance are essential for a trouble-free experience.

Final Thoughts

The Alfa Romeo 159 is a stunning car to own and drive, with a great balance of comfort and performance. While it has some known weaknesses, many are preventable or manageable if you keep on top of servicing.

To avoid unexpected repair bills, always book a CAREXAMER pre-purchase inspection. Our mobile engineers carry out over 100 checks on suspension, brakes, engine diagnostics, electronics and more — giving you full confidence before buying.

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