engine Alfa Romeo Giulia 2019 Repair Manual

pull out the bulb-bulb holder unit from
the headlight body by turning it
anticlockwise fig. 132;
remove the bulb by sliding it off the
bulb holder
install the new bulb, making sure it is
correctly inserted in the bulb holder;
then insert the bulb, bulb holder and
connector assembly in the housing on the
headlight body and turn it clockwise,
making sure that it is locked correctly;
refit the cover by tightening the fixing
screws.
Front light cluster with main
beam/dipped beam Xenon gas
discharge headlights
To replace the bulbs of the main beam
headlights/dipped headlights contact an
Alfa Romeo Dealership
WARNING
129)Before replacing the bulb, wait for the
exhaust ducts to cool down: DANGER OF
SCALDING!
130)Modifications or repairs to the electric
system that are not carried out properly or
do not take the system technical
specifications into account can cause
malfunctions leading to the risk of fire.
131)Halogen bulbs contain pressurised gas,
in the case of breakage they may burst
causing glass fragments to be projected
outwards.
132)Only replace the light bulbs when the
engine is off and in a position that does not
interfere with traffic and lets you safely
replace them (see the description in the
“Replacement” paragraph). Also ensure that
the engine is cold, to prevent the risk of
burns.
IMPORTANT
59)Halogen bulbs must be handled holding
the metallic part only. Touching the
transparent part of the bulb with your
fingers may reduce the intensity of the
emitted light and even reduce the lifespan of
the bulb. In the event of accidental contact,
wipe the bulb with a cloth moistened with
alcohol and let the bulb dry.
13108026S0021EM
13208026S0022EM
145

WARNING
133)Never replace a fuse with another with
a higher amp rating; DANGER OF FIRE.
134)Before replacing a fuse, make sure
that the ignition device is at STOP and that
all devices are switched off and/or
disconnected.
135)Contact an Alfa Romeo Dealership if a
safety system (airbags, brakes),
transmission system (engine, gearbox) or
steering system general protection fuse
blows.
136)If a fuse blows again, contact an Alfa
Romeo Dealership.
137)If a general protective fuse
(MAXI-FUSE, MEGA-FUSE, MIDI-FUSE)
blows, contact an Alfa Romeo Dealership.
IMPORTANT
60)Never replace a fuse with metal wires or
anything else.
61)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
(where provided)
DESCRIPTION
138) 139) 140) 141) 142) 143) 144) 145) 146) 147)
62)
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. 140 containing the
sealing fluid, provided with: filler tube
2 and adhesive label 3 with the writing
"Max. 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 liquid is
effective for outside temperatures
between -40°F and +122°F (-40°C and
+50°C). The sealant has an expiry date.
INFLATION PROCEDURE
138) 139) 141) 142) 143) 144) 145) 146)
Proceed as follows:
engage the electric parking brake.
Insert the tank 1 fig. 141 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;
14008066S0002EM
151

make sure that switch 5 fig. 142 of
the compressor is in position O (OFF);
insert the plug into the socket on the
central tunnel, start the engine;
start the compressor, placing the
switch 5 fig. 142 to position I (ON);
inflate the tyre to the pressure
indicated in the “Rims and Tyres”
paragraph (see “Technical data” chapter).
In order to obtain a more precise reading,check the pressure value on pressure
gauge 6 fig. 142 with the compressor off;
if after 15 minutes pressure is not at
least 26 psi (1.8 bar), disengage the
compressor from the valve and power
socket, then move the car forwards
approx. five wheel turns in order to
distribute the sealant inside the tyre
evenly, then repeat the inflation
operation;
if you still cannot obtain a pressure of
at least 26 psi (1.8 bar) within
15 minutes from the compressor
switching on, do not drive off and contact
an Alfa Romeo Dealership;
after having driven for about 5 miles
(8 km), stop, engage the electric parking
brake and recheck the tyre pressure;
if the pressure is less than 26 psi
(1.8 bar), do not go back into gear but see
an Alfa Romeo dealer;
if a pressure value of at least 26 psi
(1.8 bar) is detected, restore the correct
pressure (with engine running and
electric parking brake), resume driving
immediately and drive with great care to
an Alfa Romeo Dealership.
SEALANT BOTTLE REPLACEMENT
IMPORTANT Only use original cartridges,
which can be purchased at an Alfa Romeo
dealership.
Proceed as follows:
Remove the tank 1 fig. 143 pressingthe unhooking button 9;
insert the new tank pressing it
downwards hard.
WARNING
138)Punctures on the sides of the tire may
not be repaired. Do not use the Tire Repair
kit if the tyre was damaged as a result of
being used when underinflated.
139)Wear the protective gloves provided
with the Tire Repair kit.
140)Apply the adhesive label where it can
be easily seen by the driver as a reminder
that the tyre has been treated with the Tire
Repair Kit. Drive carefully, particularly on
bends. Do not exceed 80 km/h. Avoid sudden
acceleration or braking.
141)You must always indicate that the tyre
was repaired using the Tire Repair Kit. Give
the booklet to the technicians who will be
handling the tyre that was treated using the
Tire Repair Kit.
14108066S0004EM
14208066S0005EM
14308066S0009EM
152
IN AN EMERGENCY

EMERGENCY STARTING
If the battery is flat, a jump starting can
be performed using the battery and the
cables of another vehicle, or using an
auxiliary battery. In all cases, the battery
used must have a capacity equal to or a
little higher than the flat one.
Jump starting may be dangerous if
carried out incorrectly: carefully follow
the procedures described below.
63)
IMPORTANT NOTES
Do not use an auxiliary battery or any
other source of external supply with a
voltage above 12 V: the battery, the
starter, the alternator and the electrical
system of the vehicle could be damaged.
Do not attempt jump starting if the
battery is frozen. The battery could break
and explode!
REMOTE BATTERY CONNECTION
POLES
To facilitate the operation, the remote
poles of the battery for the jump starting
can be found in the engine compartment:
the battery, on the other hand, is placed
in the luggage compartment.
The negative terminal (-) fig. 144 fig. 8 is
positioned next to the right bonnet lock.The positive pole (+) can be accessed by
removing the cover fig. 145
open protective flap fig. 146.The pole is shown in fig. 147.
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).
14408076S0006EM
14508076S0007EM
14608076S0002EM
14708076S0001EM
154
IN AN EMERGENCY

JUMP STARTING
151) 152) 153)
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.
Cable connection
64)
Proceed as follows to carry out a jump
starting:
connect a terminal on the end of the
positive cable from the remote positive
pole (+) of the car with flat battery;
connect the terminal on the opposite
end of the positive (+) cable to the
positive (+) pole of the auxiliary battery;
connect a negative cable end terminal
to the negative (-) pole of the auxiliary
battery;
connect the terminal on the opposite
end of the negative (-) cable to the earth
point (-) on the vehicle with the battery
flat;
start the engine of the car with an
auxiliary battery, let it run for some
minutes at idle and then start the engine
of the car with flat battery. In case a
portable battery is used, before starting
the vehicle, wait a few seconds after
completing the connection.
Cable disconnection
Once the engine is started, remove the
connection cables in reverse sequence,
as shown below:
disconnect the negative cable end
terminal (-) from the earth point (-) of the
car with flat battery;
disconnect the terminal on the
opposite end of the negative cable fromthe negative (-) pole of the auxiliary
battery;
disconnect the terminal on the
opposite end of the positive (+) cable
from the positive (+) pole of the auxiliary
battery;
disconnect the terminal on the end of
the positive cable from the remote
positive pole (+) of the car with flat
battery.
WARNING
151)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.
152)Remove any metal objects (e.g. rings,
watches, bracelets), that might cause an
accidental electrical contact and cause
serious injury.
153)The batteries contain acid that can
burn skin or eyes. Batteries produce
hydrogen, which is easily flammable and
explosive. Thus keep away flames or devices
which may cause sparks.
IMPORTANT
63)Never use a fast battery-charger to
start the engine as this could damage the
electronic systems of your vehicle,
particularly the ignition and engine fuel
supply control units.
155

64)Do not connect the cable to the negative
terminal (–) of the flat battery. The following
spark could lead to battery explosion and
cause serious harm. Only use the specific
earth point; do not use any other exposed
metallic part.FUEL CUT-OFFSYSTEM
DESCRIPTION
The vehicle is equipped with a system
that cuts off the fuel supply in the event
of an impact, causing the engine to stop.
This safety device is controlled by the
ORC control unit, which manages all the
occupant protection systems. Depending
on the type and violence of the impact,
this control unit determines whether or
not to activate the airbags and the front
seatbelt pretensioners and whether or
not to immediately interrupt the current
from the batteries to the supply pumps
and to the devices that make the engine
operate. The power from the battery is
interrupted by "skipping" the pyrotechnic
fuse placed on the fusebox next to the
positive pole of the battery.
When the fuse is "skipped", only some
services, necessary for the safety of the
vehicle (eg: door locks, anti-theft device,
etc.), remain powered.
IMPORTANT After the impact, carefully
check the vehicle for fuel leaks, for
instance in the engine compartment,
under the vehicle or near the tank area.
IMPORTANT Contact an Alfa Romeo
Dealership to have the system checked.
AUTOMATIC TRANSMISSION
GEAR LEVER UNLOCKING
(where provided)
To release the automatic transmission
lever, contact an Alfa Romeo Dealership.
156
IN AN EMERGENCY

take the tow hook from its housing in
the boot and carefully clean the threaded
housing on the vehicle before using it;
tighten the vehicle's tow hook in its
place for about 11 turns.
IMPORTANT The largest work angle of
the cable to fix on the tow hook must not
exceed 15°, as shown in fig. 150.
WARNING
154)Move the ignition device to ON and
then to STOP, without opening the door.
155)The brake servo and the
electromechanical power steering will not
work while the vehicle is being towed. You
will therefore need to apply more force on
the brake pedal and steering wheel. Do not
use flexible ropes when towing, and avoid
jerky movements. During towing, make sure
that the trailer hitch does not damage any
components it is touching. When towing the
car, you must comply with all specific traffic
regulations and adopt an appropriate
driving behaviour. Do not start the engine
while towing the car. Before tightening the
ring, clean the threaded housing thoroughly.
Make sure that the ring is fully screwed into
the housing before towing the car.
14908136S0003EM
15008136S0002EM
158
IN AN EMERGENCY

Correct servicing permits the performance of the vehicle 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 CARE
SCHEDULED SERVICING.........................160
ENGINE COMPARTMENT.........................167
BATTERY RECHARGING .........................173
SERVICING PROCEDURES . . ......................174
LIFTING THE VEHICLE..........................176
WHEELS AND TYRES...........................177
BODY.....................................178
INTERIOR..................................179

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 maintenance
operations at fixed distance intervals
and, for versions/markets, where
provided, at fixed time intervals, as
described in the Service Schedule.
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
operations 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.
REGULAR CHECKS
Every year or620miles (1,000km) or
before long journeys, check and top up, if
necessary:
engine coolant level;
brake fluid level (if insufficient, see an
Alfa Romeo dealership as soon as
possible);
low AdBlue diesel emissions additive
(UREA) level warning (2.2 JTD versions
only);
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.
…ˆ
‹Š
‹Š
‹Š€…
Ž
„?
bFD>
‰…ˆA>>>
‡‰
¡

}Š€


»Šƒ…Š
ˆ
}Š€
}Ž

DEMANDING
USE
OF
THE
CAR
If
the
vehicle
is
used
in
one
of
the

following
conditions:







€‘






4-5
miles
(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 out
more often than indicated in the
Scheduled Servicing Plan:
check front and rear disc brake pad
condition and wear;
check cleanliness of bonnet and
tailgate 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 filter (where provided).
160
SERVICING AND CARE

SERVICE SCHEDULE (2.0 T4 MAir petrol engine versions)
IMPORTANT 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 18273645546372 8190
Years12345678 910
Check battery charge status with the proper instrument●●●●●●●●●●
Check tyre condition/wear and adjust pressure, if necessary.
Check quick tyre repair kit recharge conditions/expiry date
(if 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●●●●●●●●●●
Check the supply/engine control and emissions systems
operation using the diagnosis equipment●●●●●●●●●●
Check engine oil decay using the diagnosis equipment(2)●●●●●●●●●●
(1) Always only use the liquids shown in the handbook for topping up after having checked that the system is not damaged.
(2) If the engine oil quality detected by the vehicle diagnostics is lower than 20%, it is advisable to replace the engine oil and engine filter in order to avoid another service
operation after a short time.
161
Thousands ofkilometres15 30 45 60 75 90 105 120135150