gearbox Alfa Romeo Giulia 2016 User Guide

WARNING
122)Never replace a fuse with another with
a higher amp rating; DANGER OF FIRE.
123)Before replacing a fuse, make sure
that the ignition device is at STOP and that
all devices are switched off and/or
disconnected.
124)Contact an Alfa Romeo Dealership if a
safety system (airbags, brakes),
transmission system (engine, gearbox) or
steering system general protection fuse
blows.
125)If a fuse blows again, contact an Alfa
Romeo Dealership.
126)If a general protective fuse
(MAXI-FUSE, MEGA-FUSE, MIDI-FUSE)
blows, contact an Alfa Romeo Dealership.
IMPORTANT
50)Never replace a fuse with metal wires or
anything else.
51)If it is necessary to wash the engine
compartment, take care not to directly hit
the fuse box and the window wiper motors
with the water jet.
TIRE REPAIR KIT
DESCRIPTION
127) 128) 129) 130) 131) 132) 133) 134) 135)
52)
3)
The Tire Repair Kit is located in the boot,
inside a specific container.
To access the Tire Repair Kit, open the
boot, lift the load platform.
The Tire Repair Kit includes also:
one tank 1 fig. 137 containing the
sealing fluid, provided with: filler tube
2 and adhesive label 3 with the writing
"Max. 50 mph (80 km/h)”, to be attached
in a position easily visible to the driver
(eg. on the dashboard) after repairing the
tyre;
compressor 4 complete with pressure
gauge and connectors;
an instruction leaflet, to refer to for
prompt and correct use of the Tire Repair
Kit and that must be then given to the
personnel dealing with the tyre treated
with sealant;
a pair of protective gloves;
some adaptors, for inflating different
elements.
IMPORTANT The sealing fluid is effective
with external temperatures of between
-40°F (-40°C) and 122°F (+50°C). The
sealing fluid has an expiry date.
INFLATION PROCEDURE
127) 128) 130) 131) 132) 133) 134) 135)
Proceed as follows:
engage the electric parking brake.
Insert the tank 1 fig. 138 containing the
sealing liquid in the proper compressor
holder, pressing down hard. Unscrew the
tyre valve cap, take out the filler hose
2 and tighten the ring nut on the tyre
valve;
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132
IN AN EMERGENCY

The positive pole (+) can be accessed by
removing the cover fig. 142
open protective flap fig. 143.The pole is shown in fig. 144.
To carry out the operation, you need to
have the correct cables to connect the
auxiliary battery to the remote poles of
the flat battery. Usually, these cables
have terminals at the ends and are
identified by different sheath colours
(red = positive, black = negative).
JUMP STARTING
136) 137) 138)
Proceed as follows:
switch off all electrical devices in the
vehicle;
engage the parking brake, move the
lever to P (Park), for versions equipped
with automatic transmission, or neutral,
for versions with manual gearbox, then
set the ignition device to STOP;
should you be using the battery of
another vehicle, park the other vehicle
within the range of the cables used for
the connection, operate the parking
brake and ensure that its ignition is off.
IMPORTANT If the auxiliary battery is
installed on another vehicle, check that
there is no accidental contact of metal
parts between the two vehicles, since an
earth connection may result, with the risk
of serious injury to any people who may
be nearby.
IMPORTANT If the procedure below is
carried out incorrectly, it can cause
severe injury to people or damage the
recharging system of one or both
vehicles. Carefully follow the instructions
given below.
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135

SCHEDULED SERVICING
Correct servicing is crucial for
guaranteeing a long life for the vehicle
under the best conditions.
For this reason, Alfa Romeo has planned
a series of checks and services at fixed
distance intervals and, for
versions/markets, where provided, at
fixed time intervals, as described in the
Scheduled Servicing Plan.
Before each service, it is always
necessary to carefully follow the
instructions in the Scheduled Servicing
Plan (e.g. periodically check level of
fluids, tyre pressure, etc.).
Scheduled Servicing is offered by an Alfa
Romeo Dealership according to a set
time schedule. If, during each operation,
in addition to the ones scheduled, the
need arises for further replacements or
repairs, these may be carried out with the
owner's explicit consent only.
IMPORTANT Scheduled Servicing
Coupons are required by the
Manufacturer. Failure to have them
carried out may invalidate the warranty.
It is advisable to inform the Alfa Romeo
Dealership of any small operating
irregularities without waiting for the next
service.
PERIODIC CHECKS
Every year or every600mi (1,000 km) or
before long trips check and, if necessary,
top up:
engine coolant level;
brake fluid level (if insufficient, see an
Alfa Romeo dealership as soon as
possible);
windscreen washer fluid level;
tyre inflation pressure and condition;
operation of lighting system
(headlights, direction indicators, hazard
warning lights, etc.);
operation of screen washing/wiping
system and positioning/wear of wiper
blades.
Every1,800mi (3,000 km), check and
top up if required: engine oil level.
HEAVY USAGE OF THE CAR
If the vehicle is used under one of the
following conditions:
dusty roads;
short, repeated journeys (less than
4-5 mi (7-8 km)) at sub-zero outside
temperatures;
engine often idling or driving long
distances at low speeds or long periods
of inactivity;
in the event of a long period of
inactivity;
the following checks must be carried outmore often than indicated in the
Scheduled Servicing Plan:
check front and rear disc brake pad
condition and wear;
check cleanliness of bonnet and boot
locks, cleanliness and lubrication of
linkage;
visually inspect conditions of: engine,
gearbox, transmission, pipes and hoses
(exhaust/fuel system/brakes) and rubber
elements (gaiters/sleeves/bushes, etc.);
check battery charge and battery fluid
level (electrolyte);
visually inspect conditions of the
accessory drive belts;
check and, if necessary, change engine
oil and replace oil filter;
check and, if necessary, replace pollen
filter;
check and, if necessary, replace air
cleaner;
check and, if necessary, replace the
Bad Fuel fuel filter (where available).
142
SERVICING AND CARE

ENGINE OIL
144)
56)
The engine oil level can be seen on the
instrument panel display every time the
engine is started, or on the Connect
system display by activating on the main
menu (MENU button) the following
functions in sequence: “Apps”; “My Car”
and “Oil Level”.
The oil level can also be checked
manually.
Manual gearbox: checking oil level
2.2 JTD Engine
Have this operation performed at an Alfa
Romeo Dealership.
Engine oil consumption
57)
4)
The maximum engine oil consumption is
usually 0.55 pounds (250 grams) every
620 mi (1,000 km). When the vehicle is
new, the engine needs to be run in;
therefore the engine oil consumption can
only be considered stabilised after the
first 3,100 - 3,730 mi (5,000 -
6,000 km).
ENGINE COOLANT FLUID
145)
58)
If the level is too low, unscrew the cap of
reservoir 2 and add the fluid described in
the "Technical Specifications" chapter.
WASHER FLUID FOR WINDSCREEN/
HEADLIGHTS
146) 147)
The windscreen and headlights washer
fluid reservoir (where available) is
equipped with a telescopic filler.
If the level is too low, remove reservoir
cap 4 and lift the filler then add the fluid
described in the "Technical
Specifications" chapter.
IMPORTANT The headlight washing
system will not work if the liquid level is
low (situation indicated by the symbol on
the instrument panel display). The
windscreen washer will keep working. On
vehicles equipped with headlight
washers, Where provided, there is a
reference notch on the dipstick: ONLY
the windscreen/rear window washer
operates with the level below this
reference.
BRAKE FLUID
Check that the fluid is at the max. level. If
the liquid level in the tank is insufficient,
contact an Alfa Romeo Dealership to
have the system checked.
AUTOMATIC TRANSMISSION
ACTIVATIONSYSTEM OIL
4)
The transmission control oil level should
only be checked at an Alfa Romeo
Dealership.
USEFUL ADVICE FOR EXTENDING THE
LIFE OF YOUR BATTERY
Useful advice for extending the life of
your battery
To avoid draining your battery and make
it last longer, observe the following
instructions:
when you park the car, ensure that the
doors, tailgate and bonnet are closed
properly, to prevent any lights from
remaining on inside the passenger's
compartment;
switch off all roof lights inside the car:
the car is however equipped with a
system which switches all internal lights
off automatically;
do not keep accessories (e.g. radio,
hazard warning lights, etc.) switched on
for a long time when the engine is not
running;
before performing any operation on
the electrical system, disconnect the
negative battery cable.
If, after purchasing the car, you wish to
install electrical accessories which
require permanent electrical supply (e.g.
alarm, etc.) or accessories which
147

WARNING
154)The air intake system (air cleaner,
rubber hoses, etc.) can be a protection in the
case of blowbacks from the engine. DO NOT
REMOVE this system unless you need to
carry out repair or servicing operations.
Before starting the engine, ensure that the
system has not been removed: failure to
observe this precaution may result in serious
injury.
155)Exhaust emissions are very dangerous,
and may be lethal. They contain carbon
monoxide, a colourless, odourless gas which
can cause fainting and poisoning if inhaled.
156)The exhaust system may reach high
temperatures and may cause a fire if the
vehicle is parked on flammable material. Dry
grass or leaves can also catch fire if they
come into contact with the exhaust system.
Do not park or use the vehicle in a place in
which the exhaust system might come into
contact with flammable material.
IMPORTANT
61)Incorrect servicing of the vehicle or
failure to carry out operations or repairs
(when necessary) may lead to more
expensive repairs, damage to other
components or have a negative impact on
the vehicle performance. Have any
malfunction inspected immediately by an
Alfa Romeo Dealership.62)The vehicle is equipped with fluids which
are optimised or protecting its performance
and life and extending service intervals. Do
not use chemicals for washing these
components since they may damage the
engine, the gearbox or the climate control
system. This damage is not covered by the
vehicle’s warranty. If any component needs
to be washed due to malfunctioning, use only
the specific liquid for that procedure.
63)An excessive or insufficient amount of
oil inside the base is extremely damaging to
the engine. Make sure it is always at an
adequate level.
64)Vehicles equipped with catalytic
converter must be fuelled only with unleaded
petrol. Leaded petrol would permanently
damage the catalytic converter and
eliminate its ability to reduce polluting
emissions, seriously compromising the
engine performance, which would be
irreparably damaged. If the engine does not
work correctly, especially if it starts
irregularly or if there is a reduction of its
performance, immediately go to an Alfa
Romeo Dealership. Prolonged and faulty
operation of the engine may cause
overheating of the converter and, as a
consequence, possible damage to the
converter and the vehicle.
65)Using a gearbox fluid different from that
approved may compromise gearshifting
quality and/or cause vibration of the
gearbox itself.66)It is recommended to have the vehicle
serviced by an Alfa Romeo Dealership. When
carrying out normal periodic operations and
small servicing interventions personally on
the vehicle, it is recommended to use
suitable equipment, genuine spare parts and
the necessary fluids. Do not carry out any
interventions if you don't have the necessary
experience.
67)When you need to disconnect or remove
the battery, do not close the boot. In order to
avoid possible accidental closure, it is
recommended to place an obstacle (e.g. a
cloth) on the lock that would physically avoid
closure.
68)Always require the use of only
compressor coolants and lubricants
approved and suitable for the specific air
conditioning system fitted on the vehicle.
Some non-approved coolants are flammable
and may explode, with the risk of injuries. The
use of non-approved coolants or lubricants
may adversely affect system efficiency,
leading to expensive repairs.
69)The air conditioner system contains
coolant under high pressure: to avoid injuries
to people or damage to the system, any
coolant addition or repair that requires to
disconnect the cables must be carried out by
an Alfa Romeo Dealership.
152
SERVICING AND CARE

WEIGHTS
Weights (lb / kg)2.2 JTD engine
Manual gearbox Automatic transmission
Unladen weight (with all fluids, fuel tank filled to 90% and without optional equipment) 3,029 lb (1,374 kg) 3,186 lb (1,445 kg)
Payload including the driver(*)1,248lb(566kg)1,28lb
Maximum permitted loads(**)
– front axle 1,962 lb (890 kg) 2,072 lb (940 kg)
– rear axle 2,458 lb (1,115 kg) 2,524 lb (1,145 kg)
– total 4,277 lb (1,940 kg) 4,453 lb (2,020 kg)
Towable loads 3,527 lb (1,600 kg) 3,527 lb (1,600 kg)
(*) If special equipment is fitted (trailer towing equipment, etc.) the empty weight will increase and consequently the payload will decrease in relation to the maximum permitted loads.
(**) Loads not to be exceeded. The user is responsible for arranging goods in the luggage compartment and/or on the load platform within the maximum permitted loads.
164
TECHNICAL DATA
6(575

REFUELLING
2.2 JTD engine
Fuel tank (UK gal / litres) 11.44 UK gal (52 lt)
including a reserve
of (UK gal / litres) 1.76 UK gal (8 lt)
Engine cooling system (UK gal / litres) 1.72 UK gal (7.8 lt)
Engine sump and filter (UK gal / litres) 0.79 UK gal (3.6 lt) (RWD Version) / 0.88 UK gal (4 lt) (AWD Version)
Hydraulic brake circuit (UK gal / litres) 0.20 UK gal (0.9 lt)
Windscreen washer fluid reservoir (UK gal / litres) 0.92 UK gal (4.2 lt)
Automatic transmission, 2.2 JTD 180 HP RWD engine (UK gal / litres) 2.02 UK gal (9.2 lt)
Automatic transmission, 2.2 JTD 210 HP AWD engine (UK gal / litres) 2.00 UK gal (9.1 lt)
GETRAG G217 manual gearbox (UK gal / litres) 0.31 UK gal (1.4 lt)
RDU 230-LSD differential (UK gal / litres) 0.20 UK gal (0.9 lt)
RDU 210-eLSD differential (if present) (litres) 0.31 UK gal (1.4 lt)
RDU 210/215-LSD differential (UK gal / litres) 0.24 UK gal (1.1 lt)
AWD System FAD transfer case (UK gal / litres) 0.11 UK gal (0.5 lt)
AWD System TRANSFER CASE (UK gal / litres) 0.15 UK gal (0.7 lt)
165

Use Features SpecificationOriginal fluids and
lubricantsApplications
Lubricants and greases
for drive transmissionATF synthetic lubricant 9.55550-AV5TUTELA TRANSMISSION
AS 8
Contractual Technical
Reference No. F139.I11Automatic transmission
SAE 70W API
GL-4 synthetic lubricant9.55550-MZ7TUTELA TRANSMISSION
GEARSYNTH LV
Contractual Technical
Reference No. F055.N15Manual gearbox
GETRAG G217 / 2.2 JTD
engine
SAE 75W-85 synthetic
lubricant9.55550-DA9TUTELA TRANSMISSION
LS AXLE FLUID
Contractual Technical
Reference No. F059.N15Differential
RDU 230-LSD RDU
210-eLSD RDU 210/215
-LSD / 2.2 JTD engine
SAE 75W-80 APL
GL-5 synthetic lubricant9.55550-DA10TUTELA TRANSMISSION
HYPOIDE GEAR OIL
Contractual Technical
Reference no. F060.N15AWD System FAD
transfer case
SAE 75W synthetic
lubricant9.55550-DA11TUTELA TRANSMISSION
TRANSFER CASE
Contractual Technical
Reference No. F061.N15AWD System TRANSFER
CASE
Lubricants and greases
for drive transmissionNLGI 0-1 grease for
constant velocity joints
with low friction
coefficient9.55580-GRAS IITUTELA STAR 700
Contractual Technical
Reference No. F701.C07Differential side constant
velocity joints
NLGI 1-2 molybdenum
disulphide grease for high
temperatures9.55580-GRAS IITUTELA ALL STAR
Contractual Technical
Reference No. F702.G07Wheel side constant
velocity joints
Brake fluid DOT 49.55597
MS.90039TUTELA BRAKE FLUID
EXTREME HT
Contractual Technical
Reference No. F001.N15Hydraulic brakes and
clutch controls
167

Emergency braking..........122
Headlight alignment adjustment....27
Headlight alignment corrector......27
Headrests..................21
HSA (Hill Start Assist) system......67
i-Size child restraint systems......89
Identification data............158
Ignition device...............12
Important information and
recommendations..........190
Interior lights................28
ISOFIX child restraint system
(installation)...............87
Jump starting...............135
Keys
electronic key..............11
Lane Change................27
Lane Departure Warning System . . .116
Lifting the vehicle............153
Light bulbs
types of bulbs.............123
Light switch.................24
Luggage compartment..........35
Main beam headlights..........26
Automatic main beam headlights . .26
Main beam headlights (changing a
bulb)...................125
Manual gearbox..............105
Occupant protection systems......78
Paintwork (cleaning and
maintenance).............154
Park Sensors system..........113
Parking lights................26
Passive Entry (system)..........15
PBA (Panic Brake Assist) system....67
Performance (top speed)........169
Power Lock (device)............16
Prescriptions for handling the
vehicle at the end of its life.....172
Pretensioners................81
Load limiters..............82
Rain sensor.................29
RCP system.................70
Rear Back-up Camera / Dynamic
Gridlines................117
Rear seats..................19
Rear view mirrors.............23
Reconfigurable TFT display.......40
Refuelling.................165
Refuelling procedure..........118
Refuelling the vehicle..........118
Replacing a bulb.............122
Replacing an external bulb.......125
Rims and tyres...........153 ,160
Rims and tyres provided........160
SBA (Seat Belt Alert)...........80
SBA (Seat Belt Alert) System......80
SBL function................27Scheduled servicing...........142
Scheduled servicing plan (2.2 JTD
diesel engine versions)........143
Screen wiper/washer...........28
Smart washing function........29
Seat belts..................78
Seats.....................18
Servicing procedures..........151
Side bag . . .................99
Side lights..................25
Snow chains................153
Speed Limiter...............111
Split folding rear seat...........19
SRS (supplementary restraint
system)..................95
Start & Stop Evo.............110
Starting the engine............102
Starting with flat key battery......12
Steering lock . . ..............12
Steering wheel...............22
Symbols....................4
TC (Traction Control) system......67
TFT Display (3.5”) . ............38
TFT Display (7”)...............39
The keys...................11
Tire Repair Kit...............132
Towing the vehicle . ...........138
TPMS (Tyre Pressure Monitoring
System)..................75
INDEX