light Alfa Romeo Giulietta 2018 Repair Manual

FUEL CUT-OFFSYSTEM
Operation
This intervenes in the case of an impact
causing:
the fuel supply cut-off with the engine
consequently switching off;
the automatic unlocking of the doors;
the switching on of the interior lights.
The intervention of the system is
indicated by a message shown on the
display.
Carefully check the vehicle for fuel leaks,
for instance in the engine compartment,
under the vehicle or near the tank area.
125)
After a collision, turn the ignition key to
STOP to prevent the battery from
running down.
To restore the correct operation of the
car, proceed as follows:
turn the ignition key to the MAR
position;
activate the right direction indicator;
deactivate the right direction
indicator;
activate the left direction indicator;
deactivate the left direction indicator;
activate the right direction indicator;
deactivate the right direction
indicator;
activate the left direction indicator;
deactivate the left direction indicator;
ignition key turned to the OFF
position;
turn the ignition key to the MAR-ON
position.
WARNING
125)If, after an impact, you smell fuel or
notice leaks from the fuel system, do not
reactivate the system to avoid the risk of
fire.
TCT - KEY REMOVAL
The ignition key can be removed only if
the gear lever is in position P (Park).
If the battery is flat and the ignition key is
engaged, the latter is locked in position.
To remove the key manually, proceed as
follows:
apply the handbrake;
dashboard fuses (to remove, insert
your hand in housing 1 fig. 106and lower
flap 2);
using the Allen key provided (see
fig. 107) unscrew the two top screws 2
fig. 108securing cover 1;
106A0K0527C
121

Correct maintenance permits the performance of the car to be
maintained over time, as well as limited running costs and
safeguarding the efficiency of the safety systems.
This chapter explains how.
SERVICING AND MAINTENANCE
SCHEDULED SERVICING.........................126
SCHEDULED MAINTENANCE PLAN..................127
PERIODIC CHECKS............................134
DEMANDING USE OF THE CAR.....................134
CHECKING LEVELS ............................135
BATTERY RECHARGING .........................140
AIR CLEANER/POLLEN FILTER/DIESEL FILTER...........141
NOZZLES..................................141
HEADLIGHT WASHERS..........................142
BATTERY..................................142
LIFTING THE VEHICLE . .........................143
BODYWORK.................................144
INTERIOR..................................145

SCHEDULED MAINTENANCE PLAN
PETROL VERSIONS
WARNING: Once you have carried out the last intervention in the table, continue with the scheduled servicing, maintaining the
frequency indicated in the plan by marking each operation with a dot or dedicated note.
Warning: simply restarting the maintenance from the start of the plan may cause the allowed interval to be exceeded for some
operations!
Thousands of miles9 182736455463728190
Thousands of kilometres15 30 45 60 75 90 105 120 135 150
Years12345678910
Check tyre condition/wear and adjust pressure, if necessary;
check the condition/expiry date of the “Fix&Go” repair kit
(for versions/markets, where provided)
Check operation of lighting system (headlights, direction
indicators, hazard warning lights, boot, passenger
compartment, glove compartment, instrument panel warning
lights, etc.)
Check and, if necessary, top up fluid levels(1)
Check exhaust emissions
Use the diagnosis socket to check supply/engine
management systems operation, emissions and, for
versions/markets, where provided, engine oil degradation
(1) Always only use the liquids shown in the handbook for topping up after having checked that the system is not damaged.
127

Thousands of miles9 182736455463728190
Thousands of kilometres15 30 45 60 75 90 105 120 135 150
Years12345678910
Check and, if necessary, top up the Alfa TCT gearbox control
oil level (for versions/markets, where provided)(2)
Change engine oil and replace oil filter (1.4 Turbo Petrol and
1.4 Turbo MultiAir versions)(3) (o) (●)
Change engine oil and replace oil filter (1750 Turbo Petrol
versions)(4)
Replace spark plugs (1.4 Turbo Petrol and 1.4 Turbo MultiAir
versions)(5)
Replace spark plugs (1750 Turbo Petrol versions)
Replace accessory drive belt/s(6)
Replace the toothed timing drive belt(6)
(2) Check to be carried out every year for cars on the road in countries with particularly severe climates (cold countries).
(3) If the car's annual mileage is less than 10,000 km, the engine oil and filter must be replaced every year.
(o) Recommended operations
(●) Obligatory operations
(4) The actual interval for changing engine oil and replacing the engine oil filter depends on the vehicle usage conditions and is signalled by the warning light or message in
the instrument panel. In any cases, never exceed 1 year.
(5) For 1.4 Turbo Petrol and 1.4 Turbo MultiAir versions, to guarantee correct operation and prevent serious damage to the engine, it is essential to proceed as follows:
only use spark plugs specifically certified for these engines; all spark plugs should be of the same type and brand (see the “Engine” paragraph in the “Technical
specifications” section); strictly comply with the replacement intervals in the Service Schedule. It is advisable to contact an Alfa Romeo Dealership for spark plug
replacement.
(6) Areas that are not dusty: recommended maximum mileage 120,000 km. The belt must be replaced every 6 years, regardless of distance travelled. Dustyareas and/or
demanding use of the vehicle (cold climates, town use, long periods of idling): advised maximum mileage 60,000 km. Regardless of the mileage, the beltmust be
replaced every 4 years.
129

DIESEL VERSIONS
WARNING: Once you have carried out the last intervention in the table, continue with the scheduled servicing, maintaining the
frequency indicated in the plan by marking each operation with a dot or dedicated note.
Warning: simply restarting the maintenance from the start of the plan may cause the allowed interval to be exceeded for some
operations!
Thousands of miles12 24 36 48 60 72 84 96 108 120
Thousands of kilometres20 40 60 80 100 120 140 160 180 200
Years12345678910
Check tyre condition/wear and adjust pressure, if necessary;
check the condition/expiry date of the “Fix&Go” repair kit
(for versions/markets, where provided)
Check operation of lighting system (headlights, direction
indicators, hazard warning lights, boot, passenger
compartment, glove compartment, instrument panel warning
lights, etc.)
Check and, if necessary, top up fluid levels(1)
Check exhaust emissions
Use the diagnosis socket to check fuel/engine control
systems operation, emissions and engine oil decay (the latter
for versions/markets, where provided)
Visually inspect conditions of: exterior bodywork, underbody
protection, pipes and hoses (exhaust, fuel system, brakes),
rubber elements (gaiters, sleeves, bushes, etc.)
(1) Always only use the liquids shown in the handbook for topping up after having checked that the system is not damaged.
131

Thousands of miles12 24 36 48 60 72 84 96 108 120
Thousands of kilometres20 40 60 80 100 120 140 160 180 200
Years12345678910
Check windscreen/rear window wiper blade position/wear
Check operation of the windscreen wiper/washer system
and adjust jets, if necessary
Check cleanliness of bonnet and luggage compartment locks,
cleanliness and lubrication of linkage
Check handbrake lever travel and adjust, if necessary
Visually inspect conditions and wear of front and rear disc
brake pads and integrity of pad wear indicator
Visually inspect condition of the accessory drive belt(s)
Check tension of accessory drive belt (versions without
automatic tensioner)
Visually inspect conditions of toothed timing drive belt
Check and, if necessary, top up the Alfa TCT gearbox control
oil level (for versions/markets, where provided)(2)
Change engine oil and replace oil filter(3)
(2) Check to be carried out every year for cars on the road in countries with particularly severe climates (cold countries).
(3) The actual interval for changing engine oil and replacing the engine oil filter depends on the vehicle usage conditions and is signalled by the warning light or message in
the instrument panel. In any case, it must never exceed 2 years. Where the car is used mostly in urban settings you need to replace the engine oil filter every year.
132
SERVICING AND MAINTENANCE

PERIODIC CHECKS
Every 1,000 km or before long journeys,
check and, if necessary, top up the
following:
engine coolant, brake fluid and
windscreen washer fluid level;
tyre inflation pressure and condition;
operation of lighting system
(headlights, direction indicators, hazard
warning lights, etc.);
operation of screen wash/wipe system
and positioning/wear of windscreen/
rearscreen wiper blades
Check and top up, if required, the engine
oil level every 3,000 km.
IMPORTANT To find out the correct oil
quantity, always check using the dipstick.
Carry out the check with the vehicle
parked on level ground.
DEMANDING USE OF THE CAR
If the vehicle is used mainly under one of
the following conditions:
towing a trailer or caravan;
dusty roads;
short, repeated journeys (less than
7-8 km) at sub-zero outside
temperatures;
engine often idling or driving long
distances at low speeds or long periods
of inactivity;
the following checks must be carried out
more often than indicated in the
Scheduled Servicing Plan:
check front disc brake pad condition
and wear;
check cleanliness of bonnet and
luggage compartment locks, cleanliness
and lubrication of linkage;
visually inspect condition of: engine,
gearbox, transmission, pipes and hoses
(exhaust - fuel system - brakes) and
rubber elements (boots - 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.
134
SERVICING AND MAINTENANCE

ENGINE OIL
Check that the oil level is between the
MIN and MAX references on the dipstick
3.
If the level of the oil is close to or below
the MIN mark, add oil via the filler fitting
2 until the MAX mark is reached.
131)42)
Take out the engine oil dipstick 3, clean it
with a lint-free cloth and reinsert it.
Extract it again and check that the level is
between the MIN and MAX marks on the
dipstick.
Engine oil consumption
43)3)
The maximum engine oil consumption is
usually 400 grams every 1000 km. When
the car is new, the engine needs to be run
in; therefore the engine oil consumption
can only be considered stabilised after
the first 5000 - 6000 km.
ENGINE COOLANT FLUID
If the level is too low, unscrew the cap
1 of reservoir and add the fluid described
in the "Technical Specifications" chapter.
44)132)
WINDSCREEN / REAR WINDOW
WASHING FLUID
If the level is too low, raise the reservoir
cap 6 and add the fluid described in the
"Technical Specifications" chapter.
133) 134)
IMPORTANT The headlight washer
system will not operate when the fluid
level is low, even though the
windscreen/rear window washer
continues to operate. For
versions/markets, where provided, there
is a reference notch on the dipstick (see
previous pages): ONLY the
windscreen/rear window wiper operates
with the level below this reference.
BRAKE FLUID
Check that the fluid is at the max. level.
If the fluid level in the reservoir is too low,
undo the reservoir cap 4 and add the fluid
described in the "Technical
Specifications" chapter.
45)135) 136)
AUTOMATIC TRANSMISSION
ACTIVATIONSYSTEM OIL
(for versions/markets, where provided)
The transmission control oil level should
only be checked at an Alfa Romeo
Dealership.
4)
IMPORTANT
41)Be careful not to confuse the various
types of fluids while topping up: they are not
compatible with each other! Topping up with
an unsuitable fluid could severely damage
your vehicle.42)The oil level must never exceed the MAX
reference.
43)Do not add oil with specifications other
than those of the oil already in the engine.
44)Use a fluid of the same type as that
already present in the reservoir for any
topping up of the engine cooling system. The
fluid cannot be mixed with other types of
antifreeze fluids. In the event of topping up
with an unsuitable product, under no
circumstances start the engine and contact
an Alfa Romeo Dealership.
45)Prevent brake fluid, which is highly
corrosive, from coming into contact with
painted parts. Should it happen, immediately
wash with water.
WARNING
129)Never smoke while working in the
engine compartment: gas and inflammable
vapours may be present, with the risk of fire.
130)Be very careful when working in the
engine compartment when the engine is hot:
you may get burned. Do not get too close to
the radiator cooling fan: the electric fan may
start; danger of injury. Scarves, ties and
other loose clothing might be pulled by
moving parts.
131)If the engine oil is being topped up, wait
for the engine to cool down before loosening
the filler cap, particularly for vehicles with
aluminium cap (where provided). WARNING:
risk of burns!
139

HEADLIGHT WASHERS
(for versions/markets, where provided)
These are located within the front
bumper.
They are activated when the dipped
beam and/or main beam headlights are
on and the windscreen washer is
activated.
Check the correct condition and
cleanliness of nozzles at regular
intervals.
WARNING
137)Driving with worn windscreen/rear
window wiper blades is a serious hazard,
because visibility is reduced in bad weather.
IMPORTANT
46)Do not operate the windscreen wiper
with the blades lifted from the windscreen.
BATTERY
The battery 5 (see previous pages) does
not require the electrolyte to be topped
up with distilled water. A periodic check
carried out at an Alfa Romeo Dealership
is, however, necessary to check
efficiency.
INSPECTING THE CHARGE AND THE
ELECTROLYTE LEVEL
138) 139) 140) 141)
47)
5)
If necessary, replace the battery with
another original battery with the same
specifications. Follow the battery
manufacturer's instructions for
maintenance.
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.
IMPORTANT Every time the battery is
disconnected, the steering must be
initialised. This is indicated by the
appearance of the icon
. To carry out
this procedure, simply turn the steering
wheel all the way from one end to the
other or drive in a straight line for about a
hundred metres.
IMPORTANT If the charge level remains
under 50% for a long time, the battery is
damaged by sulphation, reducing its
capacity and efficiency at start-up.
The battery will also be more at risk of
freezing (this can happen as early as
-10°C). Refer to the "Vehicle inactivity"
paragraph in "Starting and driving"
chapter if the vehicle is left parked for a
long time.
142
SERVICING AND MAINTENANCE

BODYWORK
PRESERVING THE BODYWORK
Paint6)48)
Touch up abrasions and scratches
immediately to prevent the formation of
rust.
Maintenance of paintwork consists of
washing the car: the frequency depends
on the conditions and environment where
the car is used. For example, it is
advisable to wash the car more often in
areas with high environmental pollution
or salted roads.
On some versions the car may be
equipped, on request, with an exclusive
opaque paint on the roof which, in order
to be maintained intact, requires special
care: see the instructions in the warning.
49)
To correctly wash the vehicle, follow
these instructions:
if the vehicle is washed remove the
aerial from the roof;
if high pressure jets or cleaners are
used to wash the car, keep a distance of
at least 40 cm from the bodywork to
avoid damage or alteration. Bear in mind
that a build up of water could cause
damage to the car in the long term;
wash the bodywork using a low
pressure jet of water;
wipe a sponge with a slightly soapy
solution over the bodywork, frequently
rinsing the sponge;
rinse well with water and dry with a jet
of air or a chamois leather.
Dry the less visible parts (e.g. door
frames, bonnet, headlight frames, etc.)
with special care, as water may stagnate
more easily in these areas. Do not wash
the car after it has been left in the sun or
with the bonnet hot: this may alter the
shine of the paintwork.
Exterior plastic parts must be cleaned in
the same way as the rest of the vehicle.
IMPORTANT NOTES
Avoid parking under trees; the resin
dropped by trees makes the paintwork
go opaque and increases the possibility
of corrosion.
Bird droppings must be washed off
immediately and thoroughly as the acid
they contain is particularly aggressive.
Windows
Use specific detergents and clean cloths
to prevent scratching or altering the
transparency.
IMPORTANT Wipe the rear window inside
gently with a cloth following the direction
of the filaments to avoid damaging the
heating device.
Front headlights
Use a soft cloth soaked in water and
detergent for washing cars.
IMPORTANT Never use aromatic
substances (e.g. petrol) or ketones (e.g.
acetone) for cleaning the plastic lenses
of the headlights.
IMPORTANT When cleaning with a
pressure washer, keep the water jet at
least 20 cm away from the headlights.
Engine compartment
At the end of every winter, wash the
engine compartment thoroughly, taking
care not to aim the jet of water directly at
the electronic control units or at the
windscreen wiper motors. Have this
operation performed at a specialised
workshop.
IMPORTANT The washing should take
place with the engine cold and the
ignition key in the STOP position. After
the washing operation, make sure that
the various protections (e.g. rubber caps
and guards) have not been removed or
damaged.
144
SERVICING AND MAINTENANCE