Engine & fuel system
9 documented faults — symptoms, causes and workshop fixes.
Poor driveability from cold
Overview
- Affects
- All models with 940A2.000/940A3.000/940A4.000 engine codes.
- Fault codes
P0512- Remedy
- Software update
Symptoms
Engine malfunction indicator lamp (MIL) illuminated. Trouble code stored: P0512.
Cause
Engine control module (ECM) software fault.
Repair
- Carry out electrical, mechanical and component tests (as applicable) to eliminate any other possible cause(s).
- If no fault(s) found: Re-program ECM with upgraded software.
Data: Motorwise Workshop. Bulletin 1.
Engine malfunction indicator lamp (MIL) illuminated
Overview
- Affects
- All models with Diesel engines.
- Fault codes
P0237P0238P2562P2563
Symptoms
Lack of power. Possible trouble codes stored: P0237, P0238, P2562, P2563. Whistling noise from engine. White smoke coming from exhaust.
Cause
Turbocharger (TC) control pressure sensor faulty.
Internal failure of turbocharger (TC).
Repair
- Carry out electrical, mechanical and component tests (as applicable) to eliminate any other possible cause(s).
- If no fault(s) found: Replace turbocharger (TC) and turbocharger (TC) control pressure sensor.
Data: Motorwise Workshop. Bulletin 3.
Abnormal noise from intake system on overrun
Overview
- Affects
- All models with 940A3.000 engine code.
- Remedy
- Software update
Cause
Engine control module (ECM) software fault.
Repair
- Carry out electrical, mechanical and component tests (as applicable) to eliminate any other possible cause(s).
- If no fault(s) found: Re-program ECM with upgraded software. Note: To carry out an effective repair a software upgrade will be required - refer to manufacturer.
Data: Motorwise Workshop. Bulletin 11.
Coolant leak in area of exhaust gas recirculation (EGR) cooler
Cause
Exhaust gas recirculation (EGR) cooler housing cracked/broken.
Repair
- Fit modified EGR cooler housing.
Parts1 part
| Part | Part number | Qty |
|---|---|---|
| EGR cooler housing | 71772987 | 1 |
Data: Motorwise Workshop. Bulletin 12.
Engine will not start
Failure of fuel pump (FP).
Overview
- Affects
- All models with 1.6/2.0 Diesel engines, VIN 07497055-07422734.
Symptoms
Engine malfunction indicator lamp (MIL) illuminated. Poor engine performance.
Repair steps
- Carry out electrical, mechanical and component tests (as applicable) to eliminate any other possible cause(s).
- If no fault(s) found: Replace fuel pump (FP).
- Fit auxiliary wiring harness between fuel pump (FP) and vehicle wiring harness.
- Fit protective sleeve to auxiliary wiring harness multi-plug Secure auxiliary wiring harness with cable tie.
Parts
| Part | Part number | Qty |
|---|---|---|
| Fuel pump (FP) | Refer to manufacturer | 1 |
| Auxiliary wiring harness | 1379922080 | 1 |
| Protective sleeve | 1384142080 | 1 |
| Cable tie | - | 1 |
Data: Motorwise Workshop. Bulletin 13.
Engine malfunction indicator lamp (MIL) illuminated
Overview
- Affects
- All models with 1.6/2.0 Diesel engines and manual transmission or auto shift manual (ASM) transmission.
- Remedy
- Software update
Cause
SCR system control module software fault.
Repair
- Carry out electrical, mechanical and component tests (as applicable) to eliminate any other possible cause(s).
- If no fault(s) found: Check engine control module (ECM) software version. If necessary, re-program ECM with upgraded software. Re-program SCR system control module with upgraded software. Note: To carry out an effective repair a software upgrade will be required - refer to manufacturer.
Data: Motorwise Workshop. Bulletin 14.
Fuel filler flap difficult to open
Cause
Insufficient clearance fuel filler flap and fuel filler flap opening surround.
Repair
- Fit modified fuel filler flap.
Parts1 part
| Part | Part number | Qty |
|---|---|---|
| Fuel filler flap | 50515465 | 1 |
Data: Motorwise Workshop. Bulletin 15.
Stop-start system not working
Overview
- Affects
- All models with 1.4/1.6/2.0 engines and stop-start system.
- Remedy
- Software update
Symptoms
Engine malfunction indicator lamp (MIL) illuminated. Trouble code stored: P181D.
Cause
Engine control module (ECM) software fault.
Repair
- Carry out electrical, mechanical and component tests (as applicable) to eliminate any other possible cause(s).
- If no fault(s) found: Re-program engine control module (ECM) with upgraded software. Note: To carry out an effective repair a software upgrade will be required - refer to manufacturer.
Data: Motorwise Workshop. Bulletin 16.
Splashing/knocking noise from rear of vehicle when fuel tank 3/4 full
Fuel tank in contact with underside of vehicle. Fix: fit a modified part.
Overview
- Affects
- All models with 1.6/2.0 Diesel engines.
- Remedy
- Fit modified part
Repair steps
- Remove fuel tank.
- Remove foam pads from fuel tank and thoroughly clean area indicated.
- Fit rubber pads to fuel tank.
- Remove remaining foam pad from fuel tank and thoroughly clean area indicated.
- Modify rubber pad by cutting off side sections.
- Fit modified rubber pad to fuel tank.
- Refit fuel tank using new retaining bolts. Ensure fuel tank retaining bolts tightened to correct torque setting.
Parts
| Part | Part number | Qty |
|---|---|---|
| Rubber pad | 670003729 | 7 |
| Retaining bolt | 7760269 | 6 |
Data: Motorwise Workshop. Bulletin 22.
Brakes
2 documented faults — symptoms, causes and workshop fixes.
Creaking noise from rear of vehicle when driving over rough roads
Overview
- Affects
- All models.
- Remedy
- Fit modified part
- Parts
- 4 parts
Cause
Excessive friction between handbrake cable and handbrake cable guide.
Repair
- Fit modified handbrake cable guides.
- Fit modified handbrake cables.
Parts4 parts
| Part | Part number | Qty |
|---|---|---|
| Handbrake cable, left | 50502989 | 1 |
| Handbrake cable, right | 50502987 | 1 |
| Handbrake cable guide | 50525251 | 2 |
| Rivet | 46547223 | 4 |
Data: Motorwise Workshop. Bulletin 5.
Poor driveability in adverse weather conditions (snow/ice) with snow chains fitted and all weather driving mode is activated
Overview
- Affects
- All models without auto shift manual (ASM) transmission, VIN →7149089.
- Remedy
- Software update
Cause
ABS/ESP control module software fault.
Repair
- Carry out electrical, mechanical and component tests (as applicable) to eliminate any other possible cause(s).
- If no fault(s) found: Re-program ABS/ESP control module with upgraded software. Note: To carry out an effective repair a software upgrade will be required - refer to manufacturer.
Data: Motorwise Workshop. Bulletin 20.
Suspension & drivetrain
3 documented faults — symptoms, causes and workshop fixes.
Knocking/squeaking noise from rear suspension over uneven surfaces
Overview
- Affects
- All models with sport suspension.
- Remedy
- Fit modified part
- Parts
- 4 parts
Cause
Unsatisfactory design of rear shock absorber upper mounting bushes.
Repair
- Fit modified rear shock absorber upper mounting bushes.
- Apply a light coating of grease to shock absorber upper mounting bushes.
Parts4 parts
| Part | Part number | Qty |
|---|---|---|
| Shock absorber upper mounting bush | 50520153 | 4 |
| Shock absorber mounting nut set | 15503721 | 1 |
| Bolt set | 51806605 | 1 |
| Grease (Molikote PG21) | 71736440 | 1 |
Data: Motorwise Workshop. Bulletin 9.
Creaking noise from front suspension over uneven surfaces
Cause
Repair
- Apply grease to contact surfaces of front suspension lower arm rear bush.
Parts1 part
| Part | Part number | Qty |
|---|---|---|
| Grease (Petronas SP 349) | Refer to manufacturer | 1 |
Data: Motorwise Workshop. Bulletin 10.
Abnormal noise from drivetrain when driving in 1st or 2nd gear
Overview
- Affects
- All models with 1.6/1.75/2.0 engines, →2015.
- Remedy
- Fit modified part
- Parts
- 9 parts
Cause
Unsatisfactory design of intermediate driveshaft and intermediate driveshaft support bearing mounting.
Repair
- Fit modified intermediate driveshaft.
- Fit modified intermediate driveshaft support bearing mounting.
Parts9 parts
| Part | Part number | Qty |
|---|---|---|
| Intermediate driveshaft (1,6 engine) | 55237698 | 1 |
| Intermediate driveshaft (1,75/2,0 engine) | 55237699 | 1 |
| Intermediate driveshaft (2,0 engine with ASM transmission) | 55237710 | 1 |
| Bolt | 51758186 | 2 |
| Intermediate driveshaft support bearing mounting | 51892626 | 1 |
| Bolt | 51741135 | 1 |
| Nut | 46841688 | 1 |
| Nut | 51836918 | 1 |
| Nut | 51806635 | 1 |
Data: Motorwise Workshop. Bulletin 19.
Steering
1 documented fault — symptoms, causes and workshop fixes.
Knocking/creaking noise from steering wheel when driving on straight roads
Cause
Poor material characteristics of steering wheel.
Repair
- Fit modified steering wheel.
Data: Motorwise Workshop. Bulletin 21.
Clutch & gearbox
4 documented faults — symptoms, causes and workshop fixes.
Stop-start system fails to automatically re-start engine
Cause
Clutch pedal position (CPP) switch faulty.
Repair
- Renew clutch pedal position (CPP) switch.
Parts1 part
| Part | Part number | Qty |
|---|---|---|
| Clutch pedal position (CPP) switch | 50530554 | 1 |
Data: Motorwise Workshop. Bulletin 4.
Transmission shift indicator malfunction
Overview
- Affects
- All models with manual transmission.
- Remedy
- Software update
Cause
Engine control module (ECM) software fault.
Repair
- Carry out electrical, mechanical and component tests (as applicable) to eliminate any other possible cause(s).
- If no fault(s) found: Re-program engine control module (ECM) with upgraded software.
Data: Motorwise Workshop. Bulletin 8.
Abnormal noise from transmission when pulling away or when accelerating/decelerating
Overview
- Affects
- All models with manual transmission or auto shift manual (ASM) transmission, VIN →7131429.
- Remedy
- Fit modified part
- Parts
- 2 parts
Cause
Excessive free play between differential gears.
Repair
- Carry out electrical, mechanical and component tests (as applicable) to eliminate any other possible cause(s).
- If no fault(s) found: Remove transmission from vehicle and dismantle. Fit modified differential. Reassemble transmission and refit.
Parts2 parts
| Part | Part number | Qty |
|---|---|---|
| Differential (manual transmission) | 55247379 | 1 |
| Differential (ASM transmission) | 55247380 | 1 |
Data: Motorwise Workshop. Bulletin 17.
Gear lever knob cap adrift due to broken retaining clips
Overview
- Affects
- All models with manual transmission, VIN →7083949.
- Remedy
- Fit modified part
- Parts
- 2 parts
Cause
Unsatisfactory design of gear lever knob cap.
Repair
- Clean gear lever knob and apply adhesive.
- Fit modified gear lever knob cap.
Parts2 parts
| Part | Part number | Qty |
|---|---|---|
| Gear lever knob cap | 55346345 | 1 |
| Adhesive | 55243750 | 1 |
Data: Motorwise Workshop. Bulletin 18.
Air conditioning & heating
1 documented fault — symptoms, causes and workshop fixes.
Erratic air conditioning performance
Overview
- Affects
- All models with air conditioning (AC).
- Remedy
- Fit new part
- Parts
- 1 part
Cause
AC evaporator temperature sensor failure.
Repair
- Cut wires 15 cm from AC evaporator temperature sensor.
- Fit new AC evaporator temperature sensor using heatshrink solder connectors and new wiring harness.
Parts1 part
| Part | Part number | Qty |
|---|---|---|
| AC evaporator temperature sensor repair kit | 50531622 | 1 |
Data: Motorwise Workshop. Bulletin 7.
Wipers & visibility
2 documented faults — symptoms, causes and workshop fixes.
Rear screen washer not working
Symptoms
Water ingress into front footwells. Water ingress into load area. Water ingress into rear of passenger compartment.
Cause
Rear screen washer pipe split.
Repair
- Operate rear screen washer to pin-point leak. Repair rear screen washer pipe as necessary using repair kit.
Parts1 part
| Part | Part number | Qty |
|---|---|---|
| Rear screen washer pipe repair kit | 51922436 | 1 |
Data: Motorwise Workshop. Bulletin 2.
Erratic rear wiper operation
Overview
- Affects
- All models with rear screen wash/wipe system.
- Remedy
- Software update
Cause
Multifunction control module software fault.
Repair
- Carry out electrical, mechanical and component tests (as applicable) to eliminate any other possible cause(s).
- If no fault(s) found: Re-program multifunction control module with upgraded software.
Data: Motorwise Workshop. Bulletin 6.
Glossary
Technical terms used in this guide.
- MIL
- Malfunction indicator lamp — the engine warning light on the dashboard
- ECM
- Engine control module — the electronic unit that manages the engine
- VIN
- Vehicle identification number — 17 characters, found at the base of the windscreen and on the V5C logbook
- EGR
- Exhaust gas recirculation — feeds some exhaust gas back into the intake to cut emissions
- Trouble Codes
- Standardised fault codes stored by the engine control module, read with a diagnostic tool
- AC
- Air conditioning — the system that cools the cabin
- ABS/ESP
- Anti-lock braking and electronic stability programme — the system that stops the wheels locking and keeps the vehicle stable
- FP
- Fuel pump — the pump that supplies fuel from the tank
- SCR
- Selective catalytic reduction — uses Diesel Exhaust Fluid (AdBlue) to cut NOx emissions
- TC
- Turbocharger — the exhaust-driven compressor that boosts engine power
- Control Module
- A control unit for one of the vehicle's systems (engine, gearbox, brakes, body, and so on)
- Driveshaft
- The shaft that takes drive from the differential out to a wheel
- EGR Cooler
- A heat exchanger that cools exhaust gas before it is fed back into the intake
- Multi-Plug
- A multi-pin electrical connector on a wiring harness
- Multifunction Control Module
- The control module that runs shared electrical functions (lights, wipers, locking, and so on)
- Re-Program
- Update the software on a control module using the manufacturer's diagnostic tool
- Stop-Start
- The system that cuts the engine at idle and restarts it when you pull away
- Trouble Code
- A standardised fault code stored by a control module, read with a diagnostic tool
- Wiring Harness
- The bundled cables that carry power and signals around the vehicle
- Bush
- A rubber mounting that lets a suspension or body joint move without metal-to-metal contact
- Bushes
- Rubber mountings that let a suspension or body joint move without metal-to-metal contact
- Evaporator
- The air-conditioning heat exchanger in the dashboard that cools the cabin air
- Lower Arm
- A suspension link that locates the wheel at the bottom of the hub
- Recirculation
- Air-conditioning mode that recirculates cabin air instead of drawing in outside air
Frequently asked questions
What are the common faults with the Alfa Romeo Giulietta 1.6 JTDM 16V?
This guide contains 22 workshop bulletins for the Alfa Romeo Giulietta 1.6 JTDM 16V. Of these, nine concern the engine and fuel system and four the clutch and gearbox. Symptoms, causes, repair steps and part numbers are shown where supplied.
Does every Alfa Romeo Giulietta 1.6 JTDM 16V have these faults?
No. These are patterns documented across the model by workshops, not predictions for an individual vehicle. Where a fault applies only to certain vehicles or VIN ranges, that is listed with the fault.
Can I check for Alfa Romeo Giulietta 1.6 JTDM 16V faults myself?
Many of them. The documented symptoms can be seen, heard or felt during a test drive.