Worrying number of 2.0 litre engine failures due to oil starvation when engines were full of oil points a finger at oil pump failure.
Timing belt failures of 4 cylinder twin sparks extremely common. Need new belts and tensoners every 35k - 40k miles or every 4 years whichever comes first. See TSB to change them at 36k. Also need new waterpumps because pumps are driven by timing belts and if they fail the belt gets flung off. On 1.9JTDM and 2.4JTD timing belt drives waterpump and waterpump failure can fling it off in as little as 40k miles, wrecking the engine, so belts, tensioners, minot pulleys and waterpumps all need changing every 40k miles.
Problems with 156 Selaspeed gearbox actuator and long wait for replacement parts.
'Tappety' sounding engine sign that car has been run with low or dirty oil and variable valve timing has been damaged. Make sure engine has specified oil pressure.
Clonks from rear suspension mean that bolts through the aluminium suspension components have not been tightened periodically causing wear and replacement bushes take a long time to arrive.
Stoned glass headlight lenses cost £175 each to replace.
Take care to grease bonnet catch regularly as vulnerable to road spray and the safety catch can stick open. Bonnet may then fly open and wrap itself around the windscreem.
2.4 JTDs prone to cracking their alloy sumps on speed humps. Check for damage before buying, especially drain plug.
Seems to be a braking problem on diesels, which have a vacuum pump for the brake servo assistance: can feel like total failure of brakes, but only happens intermittently. Replacing master cylinder has cured it in some cases.
On 1.9 JTD if the engine smokes or the car suddenly loses power, the secondary butterflies of the swirl actuator valve may have sooted up and seized. Possible to clean but this does not guarantee it won't happen again. Really requires the inlet manifold to be changed as the part where the actuator connects to jams and does not let the butterflies open. Job can take six hours as the fuel pump and cam belt have to be removed to get at it. A coincedental fault is sooting up of the EGR valve.
Radiator, steering rack, and front wishbones all also commonly fail.
Clutch, clutch release bearing, and gearbox input shaft bearing also common failures.
Gonella Bros of Catford good 156 specialist.
Alfaman Services, 235 Imperial Drive, Rayners Lane, London HA2 7HE.
Alfa 156 steering rack issue: The bushes at each track rod end of the rack wear, producing a knocking noise over bumps. (Often confused with worn drop links or wishbone bearings.) Eventually, the steering reaction becomes sloppy. Fiat/Alfa don't supply the bushes separately, so a garage will typically recommend a rack replacement to solve the problem. Alfaman have a stock of steering rack bushes, which I think have been made by a local engineering company. Alfaman Services, 235 Imperial Drive, Rayners Lane, London HA2 7HE. Owners should contact them for a quote, replacing the bushes rather than the whole rack should save quite a lot of money. Typical rack replacement £400 + VAT.