Engine & fuel system
6 documented faults — symptoms, causes and workshop fixes.
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 1.
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 2.
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 3.
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 4.
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 5.
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 11.
Brakes
1 documented fault — symptoms, causes and workshop fixes.
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 10.
Suspension & drivetrain
1 documented fault — symptoms, causes and workshop fixes.
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 9.
Clutch & gearbox
3 documented faults — symptoms, causes and workshop fixes.
Poor gear shifting
Overview
- Affects
- All models with 2.0 Diesel engine and auto shift manual (ASM) transmission.
- Remedy
- Software update
Symptoms
Poor driveability.
Cause
ASM transmission control module software fault.
Engine control module (ECM) requires software upgrade.
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 ASM transmission 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 6.
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 7.
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 8.
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
- 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
- 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
- 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
- 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 2.0 JTDM 16V?
This guide contains 11 workshop bulletins for the Alfa Romeo Giulietta 2.0 JTDM 16V. Of these, six concern the engine and fuel system and three the clutch and gearbox. Symptoms, causes, repair steps and part numbers are shown where supplied.
Does every Alfa Romeo Giulietta 2.0 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 2.0 JTDM 16V faults myself?
Many of them. The documented symptoms can be seen, heard or felt during a test drive.