2019-2021 Alfa Romeo Stelvio & 2020-2021 Alfa Romeo Giulia Safety Recall Y24 ABS Hydraulic Control Unit

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May 4, 2021 NHTSA CAMPAIGN NUMBER: 21V309000

Rotor and Shaft May Separate Causing a Loss of ABS

 

The loss of braking assistance and ABS functionality can reduce overall braking performance, increasing the risk of a crash.

 

NHTSA Campaign Number: 21V309

Manufacturer Chrysler (FCA US, LLC)

Components SERVICE BRAKES, HYDRAULIC, SERVICE BRAKES, AIR

Potential Number of Units Affected 9

 

Summary

Chrysler (FCA US, LLC) is recalling certain 2019-2021 Alfa Romeo Stelvio and 2020-2021 Alfa Romeo Giulia vehicles. Hard braking may cause the Anti-Lock Brake System (ABS) Hydraulic Control Unit (HCU) rotor shaft to separate, a reduction of braking assist, and a loss of ABS.

 

Remedy

Dealers will replace the ABS HCU, free of charge. Owner notification letters were mailed on June 29, 2021. Owners may contact FCA US LLC customer service at 1-800-853-1403.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

 

Check if your Vehicle has a Recall

 


New Safety Recall Advanced Communication – Y24

 

FCA US LLC (FCA US) has announced a safety recall on certain 2020 and 2021 Model Year (GA) Alfa Romeo Giulia and 2019 through 2021 Model Year (GU) Alfa Romeo Stelvio vehicles.

 

VINs identified as being involved in this campaign are currently live and searchable. Stop sale is in effect for the above-identified vehicles.

 

Vehicles impacted by a stop sale are eligible for reimbursement allowance through the Recall Floorplan Reimbursement Policy (RFPRP), which can be requested upon recall claim submission.

 

IMPORTANT:  Some of the involved vehicles may be in dealer new vehicle inventory.  Federal law requires you to complete this recall service on these vehicles before retail delivery.  Violation of this requirement by a dealer could result in a civil penalty of up to $21,000 per vehicle.  Involved vehicles can be determined by using the VIP inquiry process.

 

REASON FOR THIS SAFETY RECALL

Some of the above vehicles may have been built with an Anti-Lock Brake System (ABS) Hydraulic Control Unit (HCU) with a missing or partially missing weld of the rotor to the shaft of the brushless motor. During a hard braking maneuver, the ABS HCU rotor and shaft may separate, which could lead to a reduction in braking assistance and loss of ABS functionality. Full mechanical braking is still available. The loss of braking assistance and ABS functionality may reduce the overall braking performance which can cause a vehicle crash without prior warning.

 

SERVICE ACTION

FCA US will conduct a voluntary safety recall to replace the suspect ABS HCU. The remedy for this condition is not currently available.  Dealers will be notified of the launch of this safety recall by way of established communication methods.  This recall is estimated to launch in 2nd Quarter of 2021.

 


Revision (1) August 2021

Dealer Service Instructions for:

Safety Recall Y24 / NHTSA 21V-309 ABS Hydraulic Control Unit

 

NOTE: all VINs in this recall now have parts available.

 

Remedy Available

2020 – 2021 (GA) Alfa Romeo Giulia
2019 – 2021 (GU) Alfa Romeo Stelvio

 

NOTE:  Some vehicles above may have been identified as not involved in this recall and therefore have been excluded from this recall.

 

IMPORTANT:  Some of the involved vehicles may be in dealer new vehicle inventory.  Federal law requires you to complete this recall service on these vehicles before retail delivery.  Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service.  Involved vehicles can be determined by using the VIP inquiry process.

 

Subject

The Anti-Lock Brake System (ABS) Hydraulic Control Unit (HCU) on about 9 of the above vehicles may have a missing or partially missing weld of the rotor to the shaft of the brushless motor. During a hard braking maneuver, the ABS HCU rotor and shaft may separate, which could lead to a reduction in braking assistance and loss of ABS functionality. Full mechanical braking is still available. The loss of braking assistance and ABS functionality may reduce the overall braking performance which can cause a vehicle crash without prior warning.

 

Repair

Replace the Anti-Lock Brake System (ABS) Hydraulic Control Unit (HCU).

 

Alternate Transportation

Dealers should attempt to minimize customer inconvenience by placing the owner in a loaner vehicle if the vehicle must be held overnight.

 

Parts Information 

Since there is a unique part to VIN relationship and very low volume for this campaign, part orders will be processed on the dealer’s behalf.  Upon identification of a VIN included in this recall, please send an email to campaignteam@fcagroup.com with the following details.  An order will be placed and expedited upon approval.

 

Please include the following:

  • Dealer code
  • VIN(s)

 

Parts Return

No parts return required for this campaign.

 

Special Tools

The following special tools are required to perform this repair:

  • NPN
wiTECH MicroPod II
  • NPN
Laptop Computer
  • NPN
wiTECH Software
  • C-4829A (1823015000)
Trim Stick – removing lever
  • 2000001400
Cap, Master Cylinder
  • NPN
Brake System Bleeding Equipment
  • 2000010500
Brake Switch Pliers
  • NPN
R-1234yf refrigerant recovery recycling charging station that meets SAE standard J2843

 

Service Procedure

Refer to the appropriate repair procedure based on vehicle and engine combination.

 

A. (GA) Alfa Romeo Giulia with EC2-2.0L engine.

 

  1. Position the vehicle on a suitable hoist.

 

  1. Perform the electric handbrake disengagement procedure. Connect the wiTECH diagnosis equipment to the vehicle data link connector of the vehicle, select Antilock Brake System (ABS) in the “Miscellaneous Functions” select “Electric Park Brake (EPB)”, then start the “Maintenance Mode”.

 

NOTE: After completing the ABS control module replacement, connect the wiTECH diagnosis equipment to the vehicle data link connector, go to “ABS control module” and start the “Control module replacement” procedure.

 

  1. Raise the door windows to the upper end of travel position.

 

NOTE: Disconnecting the battery when the windows are in a position other than the upper end of travel will entail the need to run the window end of travel learning procedure.

 

  1. Open the luggage compartment lid and support it so it will not close.

 

NOTE: If the luggage compartment lid closes while the battery is disconnected, it will not be possible to reopen it. The rear seat may need to be removed to gain access to the luggage compartment area.

 

  1. To be able to reopen the luggage compartment lid, even if it accidentally closes with the battery disconnected, before disconnecting the battery, it is necessary to unscrew the cap (1b), release the pull cord hooked onto it and leave it hanging out of the luggage compartment. Then, by working on the pull cord, an emergency luggage compartment lid lock release can be obtained. The pull cord operates on the lever (1a) inside (Figure 1).

 

  1. The ignition must be in the OFF position and the vehicle must remain powered down for at least 1 minute prior to proceeding.

 

  1. Remove the battery cover (1b) by releasing retainers (1a) (Figure 2).

 

  1. If equipped with an Intelligent Battery Sensor (IBS), disconnect the IBS connector.

 

  1. Press the release button (1a) then disconnect and isolate the battery negative cable (1b) from the post (1c) (Figure 3).

 

  1. Remove the console side closure (1a) by disengaging its inner retainers (1b) with the Trim Stick C-4829A (1823015000) (Figure 4).

 

  1. Unscrew the screws from the holes (1a) of the bottom trim (1b) to be removed (Figure 5).

 

  1. Move the bottom trim (1b) back and disengage the retainers (2a) (Figure 5).

 

  1. Lower the bottom trim (1b) and disconnect the electrical connections from the courtesy lights (3a) and (3b) (Figure 5).

 

  1. Remove the bottom trim (1b) (Figure 5).

 

  1. Use tool Trim Stick C-4829A (1823015000) to disconnect the retaining pin with central pin (1a) and release the air vent (2a) (Figure 6).

 

CAUTION: Carefully move the air vent (2a) only when accessing the ABS module fasteners to avoid damaging it (Figure 6). 

 

  1. Disengage from the retaining pins and remove the soundproofing cover (1a) complete with seal (1b) for the engine oil filler (Figure 7).

 

  1. Release the nut cover (1) at the base of the windshield wiper arm (Figure 8).

 

  1. Remove the nut (1a) and keep the washer (1b) (Figure 9).

 

  1. Remove the wiper arm (2a) (Figure 9).

 

NOTE: If necessary, remove the wiper arm using a suitable extractor to release the ribbed truncated cone coupling (3a) (Figure 9).  

 

  1. Working on the front right side of the windshield base trim (1a), release the hood opening cable (1b) from the retainer (1c) (Figure 10).

 

  1. Working on both sides of the windshield base trim, remove the retaining button (1a) after releasing its central pin using the appropriate tool Trim Stick C-4829A (1823015000) (Figure 11).

 

  1. Remove the side moldings (2a) by releasing retainers (2b) (Figure 11).

 

  1. Working on both sides of the windshield base trim, remove the retaining button (1a) after releasing its central pin using the appropriate tool Trim Stick C-4829A (1823015000) (Figure 12).

 

  1. Lift and move the front (2a) of the side profiles (2b) out of the way, to access the mountings under the windshield trim (Figure 12).

 

  1. Remove the retaining buttons (1a) from the windshield trim (1b), after releasing their central pins using the appropriate tool Trim Stick C4829A (1823015000) (Figure 13).

 

  1. Starting from one end (1a) gradually release the windshield base trim (1b) from the retainer profile (1c) along the windshield base (1d) (Figure 14).

 

CAUTION: Work carefully to avoid damaging the windshield (1d) and the profile (1c) (Figure 14).

 

  1. Keep the windshield base trim (1b) (Figure 14).

 

  1. Remove the screws (1a) and remove the left body reinforcement (1b) (Figure 15).

 

  1. Remove the brake/clutch fluid reservoir plug and install the Master Cylinder Cap tool 2000001400.

 

CAUTION: It is not necessary to drain the brake system to detach the ABS module. Failure to observe this requirement may mean replacing the brake calipers.

 

  1. Disconnect the electrical connection (1) for the ABS module (Figure 16).

 

  1. Disconnect the electrical connection (1) for the ABS module (Figure 17).

 

  1. Remove the connectors (1a) and disconnect the brake fluid pipes (1b) from the ABS module (Figure 18).

 

  1. Remove the attaching screw (1) of the ABS control module mounting bracket to the body (Figure 19).

 

NOTE: To facilitate the subsequent removal of the ABS control module, we advise loosening the screws attaching the aforementioned bracket to the ABS module first.  

 

  1. Using the brake switch pliers 2000010500 (1a) positioned on the rear part of the holes (1b) of the brake pedal, compress the retaining device (1c) and retract the brake pedal (1d) at the same time in order to release the pedal from the ABS module push rod (Figure 20).

 

  1. Remove the cup (1a) and the retaining device (1b) from the push rod of the ABS module (1c) (Figure 21).

 

NOTE: The retaining device must be replaced whenever the push rod is disconnected. 

 

  1. Remove the nuts (1) attaching the ABS module to the pedal unit mounting (Figure 22).

 

  1. Retract the ABS module (1a) and remove it releasing the push rod (1b) from the firewall (Figure 23).

 

  1. Remove the screw (1a) and remove the ABS control module support bracket (1b) (Figure 24).

 

  1. Apply suitable silicone grease to the convex part of the cup and position it in place on the brake pedal.

 

  1. Insert the NEW retaining device in the brake pedal, engaging the side clips.

 

  1. Install the ABS control module support bracket in position and fasten with the respective attaching screw without tightening it.

 

  1. Position the NEW ABS control module, with NEW gasket to the bulkhead then start four NEW mounting nuts.

 

  1. Tighten the ABS control module NEW mounting nuts to the prescribed torque of 22 N·m (16 ft. lbs.).

 

  1. Fasten and tighten the attaching screw of the ABS control module mounting bracket, on body side.

 

  1. Tighten the screw attaching the ABS control module mounting bracket, on the ABS control module side.

 

  1. Connect the brake fluid pipes to the ABS module, starting from the lower one and tighten the connectors manually to engage the thread correctly. Tighten the pipes to 16 N·m (12 ft. lbs.).

 

NOTE: The pipe ends must be aligned and perfectly perpendicular with respect to their seats to ensure that the connectors screw on correctly.

 

  1. Apply suitable silicone grease to the push rod of the ABS module.

 

  1. Align the ABS control unit pushrod to the brake pedal then press the brake pedal until the pushrod engages the retaining device.

 

  1. Install the left body reinforcement in its position and tighten the attaching screws.

 

  1. Engage the wiring retaining clip on the body pin.

 

  1. Connect the electrical connections of the ABS module.

 

  1. Connect the electrical connection for the brake/clutch fluid level sensor.

 

  1. Position the windshield base trim (1a) in position and engage the retaining profile (1b) along the entire windshield   base   (1c) (Figure 25).

 

NOTE: If necessary, use soapy water to facilitate inserting the trim (1a) into the retaining profile (1b) (Figure 25).

 

CAUTION: Do not press the trim (1a) excessively into the retaining profile (1b) to avoid damaging the windshield.  

 

  1. Position the windshield base trim (1a) in position and engage the retaining profile (1b) along the entire windshield   base   (1c) (Figure 26).

 

NOTE: If necessary, use soapy water to facilitate inserting the trim (1a) into the retaining profile (1b) (Figure 26).

 

CAUTION: Do not press the trim (1a) excessively into the retaining profile (1b) to avoid damaging the     windshield (Figure 26). 

 

  1. Apply the retaining buttons (2a) with central pin (Figure 26).

 

  1. Tighten the screw (3a) (Figure 26).

 

  1. Working on the right side of the Figure 26 – Windshield Trim windshield frame trim, tighten the attaching screws.

 

  1. Position the side profiles and secure them with their retaining buttons.

 

  1. Position the side moldings and engage them, then secure them with their retaining buttons.

 

  1. Engage the hood opening cable to the retainer.

 

  1. Place the windshield wiper arm (1a) in position aligning the blade (1b) with the references (1c) etched on the windshield (Figure 27).

 

  1. Insert the washer (1a) and tighten the nut (1b) to the prescribed torque of 29 N·m (21 ft. lbs.) (Figure 28).

 

  1. Open the hood and put the soundproofing cover back in its housing engaging the retaining pins.

 

  1. Check that the air vent is correctly positioned in its housing, then engage the retaining button with central pin.

 

  1. Take the lower trim and connect the electrical connections to the courtesy lights.

 

  1. Position the lower trim, engaging the retainers and fastening the attaching screws.

 

  1. Position the console side closure and engage its inner retainers.

 

  1. Bleed air from the hydraulic brake system as described in the following steps:

 

  1. Remove the wheel studs then remove the front and rear wheels.

 

CAUTION: Replace the fluid in the pressure bleeder with NEW fluid meeting the specification DOT4 MS.90039.

 

  1. Connect the bleeding equipment (1) to the brake fluid reservoir and pressurize the system (Figure 29).

 

NOTE: The operating pressure must be kept at 2 – 3 bar (29 – 43 psi) during the “First stage” and “Second stage” described below.  

 

  1. Working at the right front caliper, position the brake fluid recovery hose to the INNER bleeder screw (1) and to the recovery container. Open the INNER bleeder screw (1) and without applying any pedal pressure on the system, allow a small amount of brake fluid to drain into the recovery container. Then tighten the bleeder screw and remove the recovery hose (Figure 30).

 

  1. Repeat the above operation on the left front brake caliper.

 

  1. Working at the right rear caliper, position the brake fluid recovery hose to the bleeder screw (1) and to the recovery container. Open the bleeder screw (1) and without applying any pedal pressure on the system, allow a small amount of brake fluid to drain into the recovery container. Then tighten the bleeder screw and remove the recovery hose (Figure 31).

 

  1. Repeat the procedure for the left rear caliper.

 

  1. Working at the left front caliper, position the brake fluid recovery hose to the INNER bleeder screw (1) and to the recovery container. Open the bleeder screw and slowly press the brake pedal down fully three or more times, until there are no more air bubbles in the recovery hose. Then tighten the bleed valve to the prescribed torque of 10 N·m (89 In. lbs.) (Figure 30).

 

  1. Repeat the bleed procedure on the OUTER bleeder screw of the left front caliper.

 

  1. Repeat the above operation on the left front brake caliper.

 

  1. Connect the pipe to the valve of the rear right brake caliper. Open the valve, slowly press the brake pedal down fully three or more times, until there are no more air bubbles in the hose through which the oil flows into the container. Tighten the bleed valve to the prescribed torque of 10 N·m (89 In. lbs.) (Figure 31).

 

  1. Repeat the above operation on the rear left brake caliper.

 

  1. Connect the terminal to the dummy negative pole of the battery and check that the retainer is correctly coupled. Connect the IBS connector if equipped.

 

  1. Connect the wiTECH diagnosis equipment to the vehicle data link connector of the vehicle, go to the ABS control module in the “Miscellaneous Functions” menu and start the “Replace Control Module” and “Check Air Presence in Hydraulic System Between Control Module and Brake Caliper” procedure.

 

  1. Check that the value of FL – FR – RR – RL volumes shown on the diagnostics equipment are within the ranges shown in the table:
VERSION 200 HP 280 HP
MIN MAX MIN MAX
FL (mm3) 1440 2550 1495 2755
FR volume (mm3) 1625 2735 1790 3050
RR volume (mm3) 870 1990 870 1990
RL volume (mm3) 855 1975 855 1975

 

  1. If even only one of the values shown in the aforementioned table is higher than the reference threshold, repeat the bleeding procedure as instructed by the diagnosis equipment.

 

  1. If after repeating the bleeding procedure, the maximum values for the rear calipers are still higher than the limit values, proceed as described below on the rear calipers only.

 

  1. Find the out of tolerance caliper and remove it without disconnecting the hose.

 

  1. Turn the brake caliper very slowly several times to the various possible positions, stop the motion and keep the bleed valve pointing upwards for a few minutes.

 

  1. Install the brake caliper(s), then repeat the bleeding steps for the caliper(s) and check the volumes using the diagnosis equipment.

 

  1. Position the right side flap of the battery housing and engage the retainers.

 

  1. Check the operation of the electrical system.

 

  1. Check that the time/day etc. are correct.

 

  1. Close the hood.

 

  1. Check the operation of the windshield wiper.

 

  1. Reposition the luggage compartment lid opening cord in its housing and close the cap.

 

  1. Close the luggage compartment lid.

 

  1. The steering must be initialized after the battery has been disconnected. This will be indicated by a warning light on the instrument panel turning on. To carry out this procedure, just start the engine, turn the steering wheel from one lock to the other and put it back into the center position.

 

  1. Enable automatic electric handbrake engagement when the engine stops. Connect the wiTECH diagnosis equipment to the vehicle data link connector of the vehicle, select ABSMiscellaneous Functions”, select “Electric Park Brake (EPB)” then start the “Assembly Check” procedure.

 

  1. From the Connect system, switch automatic handbrake enable from ON > OFF and immediately after from OFF > ON.

 

  1. Remove the car from the lift.

 

B. (GA) Alfa Romeo Giulia with EEC-2.9L engine.

 

  1. Position the vehicle on a suitable hoist.

 

  1. Perform the electric handbrake disengagement procedure. Connect the wiTECH diagnosis equipment to the vehicle data link connector of the vehicle, select Antilock Brake System (ABS) in the “Miscellaneous Functions” select “Electric Park Brake (EPB)”, then start the “Maintenance Mode”.

 

NOTE: If the ABS control module is replaced, connect the wiTECH diagnosis equipment to the vehicle data link connector, go to “ABS control module” and start the “Control module replacement” procedure.

 

  1. Drain the refrigerant using an R-1234yf refrigerant recovery recycling charging station that meets SAE standard J2843.

 

  1. Let the engine run with the climate control system on for 10 – 15 minutes.

 

  1. Depending on the vehicle engine type, remove/move any parts that hinder connection of the pipes of the refrigerant recovery recycling charging refrigerant recovery recycling charging station (1a) to the corresponding climate control system re-pressurizing valves (1b) and (1c) (Figure 33).

 

  1. Unscrew the re-pressurizing valve caps (1b) and (1c) (Figure 33).

 

  1. Connect the high pressure connecting pipe (HIGH) of the device to the corresponding quick coupling valve (1b) (Figure 33).

 

NOTE: To engage the connectors (3a) on the quick coupling valves, move the knurled ring nut (3b) upward. Fasten the ring nuts (3c) after insertion (Figure 33).

 

  1. Connect the low pressure connecting pipe (LOW) to the corresponding quick coupling valve (1c) (Figure 33).

 

NOTE: To improve safety the quick couplings (3a) for the equipment connecting pipes have different       diameters: the low pressure side is larger, while the high pressure side is smaller (Figure 33).   

 

  1. Start the procedure for draining the coolant fluid, following the instructions in the equipment manual. Save the coolant, it is to be  reused.

 

  1. When draining the system, the compressor oil extracted collects in a special container (1) (Figure 34).

 

CAUTION: The oil is very hygroscopic: do not leave the containers open.  

 

  1. Raise the door windows to the upper end of travel position.

 

NOTE: Disconnecting the battery when the windows are in a position other than the upper end of travel will entail the need to run the window end of travel learning procedure.

 

  1. Open the luggage compartment lid and support it so it will not close.

 

NOTE: If the luggage compartment lid closes while the battery is disconnected, it will not be possible to reopen it. The rear seat may need to be removed to gain access to the luggage compartment area.

 

  1. To be able to reopen the luggage compartment lid, even if it accidentally closes with the battery disconnected, before disconnecting the battery, it is necessary to unscrew the cap (1b), release the pull cord hooked onto it and leave it hanging out of the luggage compartment. Then, by working on the pull cord, an emergency luggage compartment lid lock release can be obtained. The pull cord operates on the lever (1a) inside (Figure 35).

 

  1. The ignition must be in the OFF position and the vehicle must remain powered down for at least 1 minute prior to proceeding.

 

  1. Remove the battery cover (1b) by releasing retainers (1a) (Figure 36).

 

  1. If equipped with an Intelligent Battery Sensor (IBS), disconnect the IBS connector.

 

  1. Press the retainer (1a) and disconnect the terminal (1b) from the “negative dummy terminal” (1c) of the battery (1d) (Figure 37).

 

  1. Move the terminal out of the way and isolate it (1b) (Figure 37).

 

  1. Remove the console side closure (1a), by disengaging the various inner retainers (1b) using the appropriate tool Trim Stick C4829A (1823015000) (Figure 38).

 

  1. Remove the screws from the housings (1a) of the bottom trim (1b) (Figure 39).

 

  1. Release the retaining button from the housing (2a), using the special tool Trim Stick C-4829A (1823015000) (Figure 39).

 

  1. Pull down the bottom trim (1b) by releasing the inner retainers (3a) (Figure 39).

 

  1. Disconnect the electrical connection (4a) for the courtesy lights on the bottom trim (Figure 39).

 

  1. Use tool Trim Stick C-4829A (1823015000) to disconnect the retaining pin with central pin (1a) and release the air vent (2a) (Figure 40).

 

CAUTION: Carefully move the air vent (2a) only when accessing the ABS module fasteners to avoid damaging it (Figure 40).

 

  1. Release the soundproofing cover (1) from the retaining pins and remove it (Figure 41).

 

  1. Open the clip (1a) and disconnect the quick coupling of the degassing pipe (1b) (Figure 42).

 

  1. Loosen the clamp (2a) and disconnect the degassing pipe (2b) (Figure 42).

 

  1. Remove the attaching nuts (1) of the solenoid valve support bracket (Figure 43).

 

  1. Open the clip (1a) and disconnect the quick coupling (1b) of the fuel vapor supply pipe to the solenoid valve (Figure 44).

 

  1. Disconnect the electrical connection (1) for the solenoid valve (Figure 45).

 

  1. Disconnect the quick coupling (1) of the fuel vapor supply pipe to the air sleeve between air flow meter and heat exchanger (Figure 46).

 

  1. Work on the clips to disconnect the fuel vapor supply pipe to the intake manifold (1a) and remove the solenoid valve for consent of the fuel vapor passage to the intake (1b) (Figure 47).

 

  1. Loosen the clamp (1a) and disconnect the outlet tube (1b) from the air cleaner (Figure 48).

 

  1. Loosen the clamp (1) and remove the outlet tube from air cleaner to left turbocharger air inlet pipe (Figure 50).

 

  1. Release the electrical connections (1a) from the bracket (1b) and move it out of the way (Figure 51).

 

  1. Remove the nut (1a) and disconnect the connector (1b) for the pipe from the expansion valve (1c) (Figure 52).

 

CAUTION: Seal the disconnected unions with suitable plugs to prevent moisture and impurities from entering the system.

 

  1. Release the nut cover (1) at the base of the windshield wiper arm (Figure 54).

 

  1. Remove the nut (1a) and keep the washer (1b) (Figure 55).

 

  1. Remove the wiper arm (2a) (Figure 55).

 

NOTE: If necessary, remove the wiper arm using a suitable extractor to release the ribbed truncated cone coupling (3a) (Figure 55).

 

  1. Working on the front right side of the windshield base trim (1a), release the hood opening cable (1b) from the retainer (1c) (Figure 56).

 

  1. Working on both sides of the windshield base trim, remove the retaining button (1a) after releasing its central pin using the appropriate tool Trim Stick C-4829A (1823015000) (Figure 57).

 

  1. Remove the side moldings (2a) by releasing retainers (2b) (Figure 57).

 

  1. Working on both sides of the windshield base trim, remove the retaining button (1a) after releasing its central pin using the appropriate tool Trim Stick C-4829A (1823015000) (Figure 58).

 

  1. Lift and move the front (2a) of the side profiles (2b) out of the way, to access the mountings under the windshield trim (Figure 58).

 

  1. Remove the retaining buttons (1a) from the windshield trim (1b), after releasing their central pins using the appropriate tool Trim Stick C4829A (1823015000) (Figure 59).

 

  1. Starting from one end (1a) gradually release the windshield base trim (1b) from the retainer profile (1c) along the windshield base (1d) (Figure 60).

 

CAUTION: Work carefully to avoid damaging the windshield (1d) and the profile (1c) (Figure 60).

 

  1. Keep the windshield base trim (1b) (Figure 60).

 

  1. Remove the nut (1a) attaching the delivery pipe union (1b) to the condenser (Figure 61).

 

CAUTION:   Seal   the disconnected unions with suitable plugs to prevent moisture and impurities from entering the system.

 

Figure 61 – Refrigerant Pipe

 

  1. Remove the screws (1a) and remove the body reinforcement (1b) (Figure 63).

 

  1. Remove the brake/clutch fluid reservoir plug and attach the tool 2000001400.

 

CAUTION: It is not necessary to drain the brake system to detach the ABS module. Failure to observe this requirement may mean replacing the brake calipers.

 

  1. Disconnect the electrical connections (1) of the ABS module (Figure 64).

 

  1. Remove the connectors of the brake oil pipes (2) on ABS module side (Figure 64).

 

  1. Disconnect electrical connection of the brake/clutch fluid level sensor (not shown).

 

  1. Remove the screw (1) attaching the ABS module mounting bracket to the body (Figure 65).

 

NOTE: To facilitate the subsequent removal of the ABS control module, we advise loosening the screws attaching the aforementioned bracket to the ABS control module. 

 

  1. Using the brake switch pliers 2000010500 (1a) positioned on the rear part of the holes (1b) of the brake pedal, compress the retaining device (1c) and retract the brake pedal (1d) at the same time in order to release the pedal from the ABS module push rod (Figure 66).

 

  1. Remove the cup (1a) and the retaining device (1b) from the push rod of the ABS module (1c) (Figure 67).

 

NOTE: The retaining device must be replaced whenever the push rod is disconnected.

 

  1. Remove the nuts (1) attaching the ABS module to the pedal unit mounting (Figure 68).

 

Figure 68 – ABS Module Nuts

 

  1. Retract the ABS module (1a) and remove it releasing the push rod (1b) from the firewall (Figure 69).

 

  1. Remove the screw (1a) and remove the ABS control module support bracket (1b) (Figure 70).

 

  1. Apply suitable silicone grease to the convex part of the cup and position it in place on the brake pedal.

 

  1. Insert the NEW retaining device in the brake pedal, engaging the side clips.

 

  1. Install the ABS control module support bracket in position and fasten with the respective attaching screw without tightening it.

 

  1. Position the NEW ABS control module, with NEW gasket to the bulkhead then start four NEW mounting nuts.

 

  1. Tighten the ABS control module NEW mounting nuts to the prescribed torque of 22 N·m (16 ft. lbs.).

 

  1. Fasten and tighten the attaching screw of the ABS control module mounting bracket, on body side.

 

  1. Tighten the screw attaching the ABS control module mounting bracket, on the ABS control module side.

 

  1. Connect the brake fluid pipes to the ABS module, starting from the lower one and tighten the connectors manually to engage the thread correctly. Tighten the pipes to 16 N·m (12 ft. lbs.).

 

NOTE: The pipe ends must be aligned and perfectly perpendicular with respect to their seats to ensure that the connectors screw on correctly.

 

  1. Apply suitable silicone grease to the push rod of the ABS module.

 

  1. Align the ABS control unit pushrod to the brake pedal then press the brake pedal until the pushrod engages the retaining device.

 

  1. Install the left body reinforcement in its position and tighten the attaching screws.

 

  1. Engage the wiring retaining clip on the body pin.

 

  1. Connect the electrical connections of the ABS module.

 

  1. Connect the electrical connection for the brake/clutch fluid level sensor.

 

  1. Check that the pipe from the expansion valve to the fitting is not damaged.

 

WARNING: Replace the connector O-rings. Only use seal washers with an elastomeric part in HNBR, resistant to refrigerant R1234YF. The use of seal washers with another elastomeric material may increase the risk of serious leaks of coolant from the climate control system.

 

  1. Position the pipe, connect the fittings to the expansion valve, then fasten on the attaching nuts and tighten them to the prescribed torque of 8 N·m (71 In. lbs.).

 

  1. Install the pipe bracket in position and tighten the attaching nut.

 

  1. Connect the electrical connection for the linear pressure switch.

 

  1. Connect the pipe fitting, then fasten the respective attaching nut and tighten it to the prescribed torque of 8 N·m (71 In. lbs.).

 

  1. Place the outlet tube from air cleaner to left turbocharger air inlet pipe in its housing and tighten the clamps.

 

  1. Engage the pipe between heat exchanger and left turbocharger intake to the retaining clip.

 

  1. Connect the quick coupling of the air pipe between heat exchanger and left turbocharger intake.

 

  1. Connect the quick coupling of the fuel vapor supply pipe to the left turbocharger intake.

 

  1. Place the solenoid valve for consent of the fuel vapor passage to the intake in its housing, connect the fuel vapor supply pipe to the intake manifold and close the related retaining clips.

 

  1. Connect the quick coupling of the fuel vapor supply pipe to the air sleeve between air flow meter and heat exchanger.

 

  1. Connect the electrical connection of the solenoid valve.

 

  1. Connect the quick coupling of the fuel vapor supply pipe to the solenoid valve and close the respective retaining clip.

 

  1. Tighten the solenoid valve mounting bracket attaching nuts.

 

  1. Place the degassing pipe in its housing and close the respective clamp.

 

  1. Connect the quick coupling of the degassing pipe and close the respective retaining clip.

 

  1. Position the windshield base trim (1a) in position and engage the retaining profile (1b) along the entire windshield   base   (1c) (Figure 71).

 

NOTE: If necessary, use soapy water to facilitate inserting the trim (1a) into the retaining profile (1b) (Figure 71).

 

CAUTION: Do not press the trim (1a) excessively into the retaining profile (1b) to avoid damaging the windshield (Figure 71).

 

  1. Position the windshield base trim (1a) in position and engage the retaining profile (1b) along the entire windshield   base   (1c) (Figure 72).

 

NOTE: If necessary, use soapy water to facilitate inserting the trim (1a) into the retaining profile (1b) (Figure 72).

 

CAUTION: Do not press the trim (1a) excessively into the retaining profile (1b) to avoid damaging the     windshield (Figure 72).

 

  1. Apply the windshield base trim retaining buttons and engage their central pin.

 

  1. Position the side profiles and secure them with their retaining buttons.

 

  1. Position the side moldings and engage them, then secure them with their retaining buttons.

 

  1. Engage the hood opening cable to the retainer.

 

  1. Place the windshield wiper arm (1a) in position aligning the blade (1b) with the references (1c) etched on the windshield (Figure 73).

 

  1. Insert the washer (1a) and tighten the nut (1b) to the prescribed torque of 29 N·m (21 ft. lbs.) (Figure 74).

 

  1. Restore the climate control system using an R-1234yf refrigerant recovery recycling charging station that meets SAE standard J2843.

 

  1. Refill the cooling system with (2.95 Quarts / 11.2 Liters) of the prescribed fluid (MS.90032).

 

  1. Start the procedure for re-pressurizing the refrigerant fluid, following the instructions in the  equipment manual.

 

  1. Fill with the prescribed quantity of refrigerant: R1234yf 1.18 lb / .535 kg.

 

  1. Open the hood and put the soundproofing cover back in its housing engaging the retaining pins.

 

  1. Check that the air vent is correctly positioned in its housing, then engage the retaining button with central pin.

 

  1. Take the lower trim and connect the electrical connections to the courtesy lights.

 

  1. Position the lower trim, engaging the retainers and fastening the attaching screws.

 

  1. Position the console side closure and engage its inner retainers.

 

  1. Bleed air from the hydraulic brake system as described below:

 

  1. Remove the wheel studs then remove the front and rear wheels.

 

CAUTION: Replace the fluid in the pressure bleeder with NEW fluid meeting the specification DOT4 MS.90039.

 

  1. Connect the bleeding equipment (1) to the brake fluid reservoir and pressurize the system (Figure 75).

 

NOTE: The operating pressure must be kept at 2 – 3 bar (29 – 43 psi) during the “First stage” and “Second stage” described below.

 

  1. Working at the right front caliper, position the brake fluid recovery hose to the INNER bleeder screw (1) and to the recovery container. Open the INNER bleeder screw (1) and without applying any pedal pressure on the system, allow a small amount of brake fluid to drain into the recovery container. Then tighten the bleeder screw and remove the recovery hose (Figure 76).

 

  1. Repeat the above operation on the front left brake caliper.

 

  1. Working at the right rear caliper, position the brake fluid recovery hose to the bleeder screw (1) and to the recovery container. Open the bleeder screw (1) and without applying any pedal pressure on the system, allow a small amount of brake fluid to drain into the recovery container. Then tighten the bleeder screw and remove the recovery hose (Figure 77).

 

  1. Repeat the above operation on the rear left brake caliper.

 

  1. Working at the left front caliper, position the brake fluid recovery hose to the INNER bleeder screw (1) and to the recovery container. Open the bleeder screw and slowly press the brake pedal down fully three or more times, until there are no more air bubbles in the recovery hose. Then tighten the bleed valve to the prescribed torque of 10 N·m (89 In. lbs.) (Figure 76).

 

  1. Repeat the bleed procedure on the OUTER bleeder screw of the left front caliper.

 

  1. Repeat the above operation on the left front brake caliper.

 

  1. Connect the pipe to the valve of the rear right brake caliper. Open the valve, slowly press the brake pedal down fully three or more times, until there are no more air bubbles in the hose through which the oil flows into the container. Tighten the bleed valve to the prescribed torque of 10 N·m (89 In. lbs.) (Figure 77).

 

  1. Repeat the above operation on the rear left brake caliper.

 

  1. Connect the car’s electrical system.

 

  1. Connect the terminal to the dummy negative pole of the battery and check that the retainer is correctly coupled. Connect the IBS connector if equipped.

 

  1. Connect the wiTECH diagnosis equipment to the vehicle data link connector of the vehicle, go to the ABS control module in the “Miscellaneous Functions” menu and start the “Replace Control Module” and “Check Air Presence in Hydraulic System Between Control Module and Brake Caliper” procedure.

 

  1. Check that the value of FL – FR – RR – RL volumes shown on the diagnosis equipment are within the ranges shown in the table:
VERSION STEEL DISCS CARBON-CERAMIC DISCS
MIN MAX MIN MAX
FL (mm3) 1450 2560 1900 3110
FR volume (mm3) 1580 2690 2190 3400
RR volume (mm3) 830 1920 750 1840
RL volume (mm3) 815 1905 735 1825

 

  1. If even only one of the values shown in the aforementioned table is higher than the reference threshold, repeat the bleeding procedure as instructed by the diagnosis equipment.

 

  1. If after repeating the bleeding procedure, the maximum values for the rear calipers are still higher than the limit values, proceed as described below on the rear calipers only.

 

  1. Find the out of tolerance caliper and remove it without disconnecting the hose.

 

  1. Turn the brake caliper very slowly several times to the various possible positions, stop the motion and keep the bleed valve pointing upwards for a few minutes.

 

  1. Install the brake caliper(s), then repeat the bleeding steps for the caliper(s) and check the volumes using the diagnosis equipment.

 

  1. Position the right side flap of the battery housing and engage the retainers.

 

  1. Close the hood.

 

  1. Check the operation of the windshield wiper.

 

  1. Check the operation of the electrical system.

 

  1. Check that the time/day etc. are correct.

 

  1. Reposition the luggage compartment lid opening cord in its housing and close the cap.

 

  1. Close the luggage compartment lid.

 

  1. The steering must be initialized after the battery has been disconnected. This will be indicated by a warning light on the instrument panel turning on. To carry out this procedure, just start the engine, turn the steering wheel from one lock to the other and put it back into the center position.

 

  1. Enable automatic electric handbrake engagement when the engine stops. Connect the wiTECH diagnosis equipment to the vehicle data link connector of the vehicle, select ABSMiscellaneous Functions”, select “Electric Park Brake (EPB)” then start the “Assembly Check” procedure.

 

  1. From the Connect system, switch automatic handbrake enable from ON > OFF and immediately after from OFF > ON.

 

  1. Remove the car from the lift.

 

C. (GU) Alfa Romeo Stelvio with EC2-2.0L engine.

 

  1. Position the vehicle on a suitable hoist.

 

  1. Perform the electric handbrake disengagement procedure. Connect the wiTECH diagnosis equipment to the vehicle data link connector of the vehicle, select Antilock Brake System (ABS) in the “Miscellaneous Functions” select “Electric Park Brake (EPB)”, then start the “Maintenance Mode”.

 

NOTE: If the ABS control module is replaced, connect the wiTECH diagnosis equipment to the vehicle data link connector, go to “ABS control module” and start the “Control module replacement” procedure.

 

  1. Raise the door windows to the upper end of travel position.

 

NOTE: Disconnecting the battery when the windows are in a position other than the upper end of travel will entail the need to run the window end of travel learning procedure.

 

  1. Open the luggage compartment lid and support it so it will not close.

 

NOTE: If the luggage compartment lid closes while the battery is disconnected, it will not be possible to reopen it. The rear seat may need to be folded down to gain access to the luggage compartment area.

 

  1. To be able to reopen the luggage compartment lid, even if it accidentally closes with the battery disconnected, before disconnecting the battery it is necessary to Remove cover (1b) on the luggage compartment lid (1a). There is a cable (2a) that is attached to the cover that will pull out of the opening. Leave it hanging out of the luggage compartment. Then pull the cable to release the luggage compartment lid latch (Figure 79).

 

  1. Using the handle (1b), lift out the load floor cover (1a) (Figure 80).

 

  1. Remove the battery cover (1a). (Figure 81).

 

  1. If equipped with an Intelligent Battery Sensor (IBS), disconnect the IBS connector.

 

  1. Press the retainer (1a) and disconnect the terminal (1b) from the “negative dummy terminal” (1c) of the battery (1d) (Figure 82).

 

  1. Move the terminal out of the way and isolate it (1b) (Figure 82).

 

  1. Remove the console side closure (1a), by disengaging the various inner retainers (1b) using the appropriate tool    2000040516 (Figure 83).

 

  1. Remove the screws from the housings (1a) of the lower lining (1b) (Figure 84).

 

  1. Release the retaining button from the housing (2a), using the special tool Trim Stick C-4829A (1823015000) (Figure 84).

 

  1. Pull down the lower lining (1b) by releasing the inner retainers (3a) (Figure 84).

 

  1. Disconnect the electrical connection (4a) for the courtesy lights on the lower lining(Figure 84).

 

  1. Use tool Trim Stick C-4829A (1823015000) to disconnect the retaining pin with central pin (1a) and release the air vent (2a)

(Figure 85).

 

CAUTION: Carefully move the air vent (2a) only when accessing the ABS module fasteners to avoid damaging it.

 

  1. Remove the screws (1a) and remove the strut bar (1b) (Figure 86).

 

  1. Disengage covers (1a) of the cover (1b) and remove the screws (1c) (Figure 87).

 

  1. Disengage from the rear retaining pins and remove the soundproofing cover (1b) complete with seal (2a) for the engine oil (Figure 87).

 

  1. Release from its housing the pipe (1a) of the windshield wiper arm (1b) or (1c) that is being detached (Figure 88).

 

  1. Disconnect the electrical connection (2a) for the concerned windshield wiper arm (1b) or (1c) (Figure 88).

 

  1. Disconnect the quick connector (3a) of the pipe (1a) that is being detached (Figure 88).

 

  1. Release the nut cover (4a) at the base of the windshield wiper arm that is being detached (Figure 88).

 

  1. Working on the right side of the windshield frame trim (1a), remove the screws (1b) (Figure 90).

 

  1. Working on the left side of the windshield frame trim (1a), remove the screw (1b) (Figure 91).

 

  1. Remove the retaining buttons (2a) with central pin, using the appropriate tool Trim Stick C-4829A (1823015000) (Figure 91).

 

  1. Starting from one end (3a), gradually release the windshield frame trim (1a) from the retaining profile (3b) along the windshield base (3c) (Figure 91).

 

CAUTION: Work carefully to avoid damaging the windshield (3c) and the profile (3b) (Figure 91).

 

  1. Keep the windshield base trim (1a) (Figure 91).

 

  1. Remove the screws (1a) that secure the windshield wiper assembly (1b) (Figure 93).

 

  1. Move the windshield wiper assembly (1b) slightly and disconnect the electrical connection (2a) from the windshield wiper motor (Figure 93).

 

  1. Keep the windshield wiper assembly (3) (Figure 93).

 

  1. Remove the brake/clutch fluid reservoir plug and install the tool 2000001400.

 

CAUTION: It is not necessary to drain the brake system to detach the ABS module. Failure to observe this requirement may mean replacing the brake calipers.

 

  1. Release the wiring (1a) and disconnect the electrical connection (1) for the upper oxygen sensor (Figure 94).

 

  1. Disconnect the electrical connection (1) of the brake fluid minimum level warning light switch (Figure 95).

 

  1. Disconnect the electrical connection (1) of the ABS control module (Figure 96).

 

  1. Disconnect the electrical connection (1) of the ABS control module (Figure 97).

 

  1. Unscrew the connectors (1a) and disconnect the brake fluid pipes (1b) from the ABS control module (Figure 98).

 

  1. Remove the nut (1a) and disconnect the earth lead (1b) from the body (Figure 99).

 

  1. Remove the attaching screw (1) of the ABS control module mounting bracket to the body (Figure 100).

 

NOTE: To facilitate the subsequent removal of the ABS control module, we advise loosening the screws attaching the aforementioned bracket to the ABS module first.

 

  1. Using the brake switch pliers 2000010500 (1a) positioned on the rear part of the holes (1b) of the brake pedal, compress the retaining device (1c) and retract the brake pedal (1d) at the same time in order to release the pedal from the ABS module push rod (Figure 101).

 

  1. Remove the cup (1a) and the retaining device (1b) from the push rod of the ABS control module (1c) (Figure 102).

 

NOTE: The retaining device must be replaced whenever the push rod is disconnected.

 

  1. Remove the nuts (1) attaching the ABS module to the pedal unit mounting (Figure 103).

 

  1. Retract the ABS module (1a) and remove it releasing the push rod (1b) from the firewall (Figure 104).

 

  1. Remove the screw (1a) and remove the ABS control module support bracket (1b) (Figure 105).

 

  1. Apply suitable silicone grease to the convex part of the cup and position it in place on the brake pedal.

 

  1. Insert the NEW retaining device in the brake pedal, engaging the side clips.

 

  1. Install the ABS control module support bracket in position and fasten the respective attaching screw without tightening it.

 

  1. Position the NEW ABS control module, with NEW gasket to the bulkhead then start four NEW mounting nuts.

 

  1. Tighten the ABS control module NEW mounting nuts to the prescribed torque of 22 N·m (16 ft. lbs.).

 

  1. Fasten and tighten the attaching screw of the ABS control module mounting bracket, on body side.

 

  1. Tighten the screw attaching the ABS control module mounting bracket, on the ABS control module side.

 

  1. Connect the brake fluid pipes to the ABS module, starting from the lower one and tighten the connectors manually to engage the thread correctly. Tighten the pipes to 16 N·m (12 ft. lbs.).

 

NOTE: The pipe ends must be aligned and perfectly perpendicular with respect to their seats to ensure that the connectors screw on correctly.

 

  1. Apply suitable silicone grease to the push rod of the ABS module.

 

  1. Align the ABS control unit pushrod to the brake pedal then press the brake pedal until the pushrod engages the retaining device.

 

  1. Engage the wiring retaining clip on the body pin.

 

  1. Connect the electrical connections of the ABS module.

 

  1. Connect the electrical connection for the brake/clutch fluid level sensor.

 

  1. Connect the electrical connection of the windshield wiper motor and place the windshield wiper unit in its housing.

 

  1. Tighten the attaching screws of the windshield wiper unit and tighten them to the prescribed torque of 8 N·m (71 In. lbs.).

 

  1. Position the left bar (1a), and tighten the screws (1b) and the nut (1c) to the prescribed torque of 20 N·m (15 ft. lbs.) (Figure 106).

 

  1. Secure the rod (2a) to the retainers (2b) and the band (1c) (Figure 106).

 

  1. Apply the band (3a) (Figure 106).

 

  1. Position the windshield base trim (1a) in position and engage the retaining profile (1b) along the entire windshield   base   (1c) (Figure 107).

 

NOTE: If necessary, use soapy water to facilitate inserting the trim (1a) into the retaining profile (1b) (Figure 107).

 

CAUTION: Do not press the trim (1a) excessively into the retaining profile (1b) to avoid damaging the     windshield (Figure 107).

 

  1. Apply the retaining buttons (2a) with central pin (Figure 107).

 

  1. Tighten the screw (3a) (Figure 107).

 

  1. Working on the right side of the windshield frame trim, tighten the attaching screws.

 

  1. Place the windshield wiper arm (1a) in position aligning the blade (1b) with the references (1c) etched on the windshield (Figure 108).

 

  1. Insert the washer (1a) and tighten the nut (1b) to the prescribed torque of 29 N·m (21 ft. lbs.) (Figure 109).

 

  1. Engage the nut cover (1) (Figure 110).

 

  1. Connect the quick connector (2a) of the pipe (2b) concerned (Figure 110).

 

  1. Connect the concerned electrical connection (3a) (Figure 110).

 

  1. Place the pipe (2b) concerned in position (Figure 110).

 

  1. Put the soundproofing cover back in its housing engaging the retaining pins.

 

  1. Check that the air vent is correctly positioned in its housing, then engage the retaining button with

 

  1. Take the lower trim and connect the electrical connections to the courtesy lights.

 

  1. Position the lower trim, engaging the retainers and fastening the attaching screws.

 

  1. Position the console side closure and engage its inner retainers.

 

  1. Bleed air from the hydraulic brake system as described below:

 

  1. Remove the wheel studs then remove the front and rear wheels.

 

 CAUTION: Replace the fluid in the pressure bleeder with NEW fluid meeting the specification DOT4 MS.90039.

 

  1. Connect the bleeding equipment (1) to the brake fluid reservoir and pressurize the system (Figure 111).

 

 NOTE: The operating pressure must be kept at 2 – 3 bar (29 – 43 psi) during the “First stage” and “Second stage” described below.

 

  1. Working at the right front caliper, position the brake fluid recovery hose to the INNER bleeder screw (1) and to the recovery container. Open the INNER bleeder screw (1) and without applying any pedal pressure on the system, allow a small amount of brake fluid to drain into the recovery container. Then tighten the bleeder screw and remove the recovery hose (Figure 112).

 

  1. Repeat the above operation on the left front brake caliper.

 

  1. Working at the right rear caliper, position the brake fluid recovery hose to the bleeder screw (1) and to the recovery container. Open the bleeder screw (1) and without applying any pedal pressure on the system, allow a small amount of brake fluid to drain into the recovery container. Then tighten the bleeder screw and remove the recovery hose (Figure 113).

 

  1. Repeat the above operation on the left rear brake caliper.

 

  1. Working at the left front caliper, position the brake fluid recovery hose to the INNER bleeder screw (1) and to the recovery container. Open the bleeder screw and slowly press the brake pedal down fully three or more times, until there are no more air bubbles in the recovery hose. Then tighten the bleed valve to the prescribed torque of 10 N·m (89 In. lbs.) (Figure 112).

 

  1. Repeat the bleed procedure on the OUTER bleeder screw of the left front caliper.

 

  1. Repeat the above operation on the left front brake caliper.

 

  1. Connect the pipe to the valve of the rear right brake caliper. Open the valve, slowly press the brake pedal down fully three or more times, until there are no more air bubbles in the hose through which the oil flows into the container. Tighten the bleed valve to the prescribed torque of 10 N·m (89 In. lbs.) (Figure 113).

 

  1. Repeat the above operation on the rear left brake caliper.

 

  1. Connect the terminal to the dummy negative pole of the battery and check that the retainer is correctly coupled. Connect the IBS connector if equipped.

 

  1. Connect the wiTECH diagnosis equipment to the vehicle data link connector of the vehicle, go to the ABS control module in the “Miscellaneous Functions” menu and start the “Replace Control Module” and “Check Air Presence in Hydraulic System Between Control Module and Brake Caliper” procedure.

 

  1. Check that the value of FL – FR – RR – RL volumes shown on the diagnostics equipment are within the ranges shown in the table:
VERSION MIN MAX
FL (mm3) 1495 2755
FR volume (mm3) 1790 3050
RR volume (mm3) 870 1990
RL volume (mm3) 855 1975

 

  1. If even only one of the values shown in the aforementioned table is higher than the reference threshold, repeat the bleeding procedure as instructed by the diagnosis equipment.

 

  1. If after repeating the bleeding procedure, the maximum values for the rear calipers are still higher than the limit values, proceed as described below on the rear calipers only.

 

  1. Find the out of tolerance caliper and remove it without disconnecting the hose.

 

  1. Turn the brake caliper very slowly several times to the various possible positions, stop the motion and keep the bleed valve pointing upwards for a few minutes.

  1. Install the brake caliper(s), then repeat the bleeding steps for the caliper(s) and check the volumes using the diagnosis equipment.

 

  1. Close the hood.

 

  1. Check the operation of the windshield wiper.

 

  1. Position the right side flap of the battery housing and engage the retainers.

 

  1. Check the operation of the electrical system.

 

  1. Check that the time/day etc. are correct.

 

  1. Reposition the luggage compartment lid opening cord in its housing and close the cap.

 

  1. Install the battery cover.

 

  1. Install the load floor cover.

 

  1. Close the luggage compartment lid.

 

  1. The steering must be initialized after the battery has been disconnected. This will be indicated by a warning light on the instrument panel turning on. To carry out this procedure, just start the engine, turn the steering wheel from one lock to the other and put it back into the center position.

 

  1. Enable automatic electric handbrake engagement when the engine stops. Connect the wiTECH diagnosis equipment to the vehicle data link connector of the vehicle, select ABS “Miscellaneous Functions”, select “Electric Park Brake (EPB)” then start the “Assembly Check” procedure.

 

  1. From the Connect system, switch automatic handbrake enable from ON > OFF and immediately after from OFF > ON.

 

  1. Remove the car from the lift.

 



5 Affected Products

Vehicles

MAKE MODEL YEAR
ALFA ROMEO GIULIA 2020-2021
ALFA ROMEO STELVIO 2019-2021

 


12 Associated Documents

Manufacturer Notices(to Dealers,etc) – NSRAC re FCA US LLC (FCA US) has announced a safety recall on certain 2020 and 2021 Model Year (GA) Alfa Romeo Giulia and 2019 through 2021 Model Year (GU) Alfa Romeo Stelvio vehicles

RCMN-21V309-7587.pdf 100.079KB

RCMN-21V309-7587

 


Recall Quarterly Report #1, 2021-2

RCLQRT-21V309-3414.PDF 211.147KB

RCLQRT-21V309-3414

 


Defect Notice 573 Report

RCLRPT-21V309-3256.PDF 215.383KB

RCLRPT-21V309-3256

 


ISSUED Interim Owner Notification Letter(Part 577)

RIONL-21V309-0140.pdf 303.485KB

RIONL-21V309-0140

 


Manufacturer Notices(to Dealers,etc) – Message re FCA US LLC (FCA US) has announced a safety recall on certain 2020 and 2021 Model Year (GA) Alfa Romeo Giulia and 2019 through 2021 (GU) Alfa Romeo Stelvio vehicles.

RCMN-21V309-9993.pdf 96.496KB

RCMN-21V309-9993

 


ISSUED Owner Notification Letter(Part 577)

RCONL-21V309-2558.pdf 515.382KB

RCONL-21V309-2558

 


Recall Acknowledgement

RCAK-21V309-8458.pdf 645.263KB

RCAK-21V309-8458

 


Remedy Instructions and TSB

RCRIT-21V309-0432.pdf 3122.299KB

RCRIT-21V309-0432

 


Recall Quarterly Report #2, 2021-3

RCLQRT-21V309-5207.PDF 211.241KB

RCLQRT-21V309-5207

 


Remedy Instructions and TSB

RCRIT-21V309-5490.pdf 3110.122KB

RCRIT-21V309-5490

 


ISSUED Renotification Notice

RCRN-21V309-1412.pdf 772.396KB

RCRN-21V309-1412

 


Recall Quarterly Report #3, 2021-4

RCLQRT-21V309-1264.PDF 211.32KB

RCLQRT-21V309-1264

 


Latest Recalls Documents

For the Latest and Most Recent Recalls Information Visit the link below…

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=21V309&docType=RCL

 


 

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  • 【All OBD2 Test Modes 】 This ABS & SRS scan tool is also a full featured obd2 code reader, allowing a quick test of the engine system of OBD II vehicles, can Read/Clear engine light codes, Live Data, Freeze Frame, Retrieving I/M Readiness Status, O2 Monitor Test, On-Board Monitor Test, Evap Test, Read Vehicle Information, and help pass smog test for most post-1996 OBD2/CAN vehicles.
  • [DTC LookUp Library] Can't read the code? Go to the DTC LookUp Library. The Topdon AL600 OBD2 scanner offers a wealth of code definitions so you don't have to look them up in a list or database, and the HELP function takes you to diagnostic tips for possible fixes, saving time searching for repair materials online. No other scan tool or code reader under $100 offers this level of assistance.
  • [User-Oriented] You'll love the feel of this automotive scanner, with black rubber grips all around the outer edges for durability and to withstand accidental drops. With its easy access menu, you can operate all functions in minutes with just a few button presses. The 3-color LEDs give you a intuitive indication of the OBD2 test results in a second. 3 shortcut keys, one key to read/clear DTCs and a one-touch smoke status check make it easy to use even for beginners.
SaleBestseller No. 2
FOXWELL NT630 Plus OBD2 Scanner Diagnostic Tool, ABS Scan Tool Bleeding Brake SRS Scanner Car Code Reader Bidirectional Control with Airbag Light Reset SAS Oil Light EPB Service
  • Best Choice for ABS Bleeder Scan Tool - Was the brake pedal always slowly sinking down or becoming loose? This abs brake bleeding scan tool will bleed the brake system by cycling the pump and valves to achieve a tight brake pedal. It's the most affordable obd2 scanner with abs auto bleed function you can find. With the clear step by step instruction, even a beginner can use it. Coverage check on FOXWELL official site: Support- Diagnostic Coverage List.
  • More Than a Entry Level OBD Scanner, Ideal for Home Mechanics - Based on the NT301 FOXWELL Scanner, NT630 Plus takes OBD diagnostics to the next level by customizing all functions for ABS and SRS systems. This srs abs scanner provides in-depth insights on error code diagnosis, wheel speed sensor live data, airbag circuits and cable connectors monitor, module activation and etc. It's an total game-changer in resolving ABS SRS issues.
  • No More Higher End Service than You Needed - One NT630 Plus is enough! This obd2 scanner with abs and srs takes depth diagnosis on Anti-Lock Brake System & Supplemental Restraint System, and also performs daily required resetting services which same priced scanners cannot do. Like Airbag light reset/ SAS(Steering Angle Sensor) adjustment/ Oil light reset and EPB service functions. this car scanner will help the part to operate normally after the faults repaired.
  • Also can Work like NT301 - The NT630 Plus abs code reader connect to the OBD2 port directly. It will diagnose all obd2 modules instantly, displays the live data, locates bad sensors and I/M readiness status before the annual inspection. Guides you to do the maintenance work, reduces the potential driving risk and keep a peak performance on the road.
  • Complicate? Unreadable? - Intuitive LCD display with clear operate instructions, even a beginner can diagnose the car faults with the NT630 Plus. Ergonomic Touch with anti-collision and anti-slip cover design, comfortable for daily car diagnose work. Unique button press sound will provide the overall tactile and visual experience to notice you a task has been completed or a command has been executed.
Bestseller No. 3
FOXWELL Car Scanner NT604 Elite OBD2 Scanner ABS SRS Transmission, Check Engine Code Reader,Diagnostic Scan Tool with SRS Airbag Scanner, Car Diagnostic Scanner for All Cars with Battery Test
  • 🎄【Easy to Use--Work out of box】+【FOXWELL 2024 New Version】 FOXWELL NT604 Elite scan tool is the 2024 new version from FOXWELL, which is designed for those car owners who want to figure out the cause issue before fixing the car problem via scanning the most common systems like abs srs engine and transmission.The NT604 Elite diagnostic tool comes with latest software, which can be used out of box. No need to waste time to download the software first.
  • 🎅【Affordable】+【Reliable Car Health Monitor】 Will you be confused what happen when the warning light of abs/srs/transmission/check engine flashes? Instead of taking your cars to dealership, this foxwell scanner will help you do a thorough scanning and detection for your cars and pinpoint the root cause. It will t-urn off the warning light car after the problem is fixed.👉TIPS: Airbag crash/collision data can NOT be cleared even you replace the new airbag.
  • 🎄【5 in 1 Diagnostic Scanner】Compared with those auto scanners (50-100), NT604 Elite code scanner not only includes their OBDII diagnosis but also it can be an abs/srs scanner, transmission and check engine code reader. When it’s an odb2 scanner, you can use it to check if your car is ready for annual test through I/M readiness menu. In addition, live data stream, built-in DTC library, data play back and print, all these features are a big plus for it.
  • 🎅【Fantastic AUTOVIN】+【No extra software fee】Through the AUTOVIN menu, this NT604 Elite car scanner allows you to get your V-IN and vehicle info rapidly, no need to take time to find your V-IN and input one by one. What's more, the NT604 Elite abs srs scanner supports 60+ car makes from worldwide (America/Asia/Europe). You don’t need to pay extra software fee.
  • 🎄【Solid protective case KO plastic carrying bag】+ 【Lifetime update】Almost all same price-level obd scanner diagnostic tool only offers plastic bag to hold on the scanner.However, NT604 Elite automotive scanner is equipped with solid protective case, preventing your obd2 scanner from damage. Then you don’t need to pay extra money to buy a solid toolbox.
Bestseller No. 4
Autel AutoLink AL619 Scanner, 2024 Newest Car ABS SRS & CAN OBD2 Diagnostic Scan Tool, 10 OBDII Test Modes, DTCs Lookup, Live Data, Check Engine Light Code Reader, Upgraded of ML619 AL519 ML519 AL319
  • 🎉【2024 Upgraded Ver. of AL519/ ML519/ ML619】Autel develops the brand-new AutoLink AL619 as the advanced ver. of Autel ML519, AL519, AL319, MS309. This AL619 OBD2 scanner can scan ABS & SRS systems, and support 10 Modes of OBD II Diagnostics Function on Worldwide Vehicles to read, erase codes and turn off the MIL, ABS, SRS warning lights so that you can better maintain your car when related malfunctions occur and make your vehicle ready for the annual test.
  • 🎉【Accurate ABS/ SRS Diagnostics Functions】The ABS/ SRS diagnostic function is used to retrieve and clear codes from the ABS/ SRS systems. It can read and clear DTCs, show definitions of each code, display live data of multiple sensors in the graph to locate fault causes, and assist home mechanics to do the proper repair and clear ABS & Airbag warning lights. Diagnoses ABS/ SRS system codes on most 1996 and newer major vehicle models. Please email 📩 immoautel @ outlook. com 📩 for help.
  • 🎉【All 10 Modes of OBD II Diagnostics Function】The OBD II Diagnostics function is a fast-access option that allows you to carry out a quick test on the engine system of OBD II vehicles. Read Codes, Erase Codes, Live Data, Freeze Frame, Retrieving I/M Readiness Status, O2 Monitor Test, On-Board Monitor Test, DTC Lookup, Component Test, Viewing Vehicle Information, Modules Present.
  • 🎉【Live Data and Freeze Frame Data】With Live Data functions, Autel AL619 OBD2 diagnostic code reader allows you to view the live PID (Parameter Identification Data) of the vehicle's computer module(s) in text, graph to check the status of various sensors. And Freeze Frame Data enables you to view the vehicle's operating parameters at the moment a DTC is detected. These information will aid the technician by allowing the parameters to be duplicated for diagnostic and repair purposes.
  • 🎉【DTC Lookup Feature】Besides showing you the code’s definition while you are reading the diagnostic trouble codes, AL619 features comparably user-friendly DTC Lookup Function which enables you to retrieve the definitions of any error codes from the large database of AL619, saving you from the hassle of wasting time searching definition of every code via Google.
SaleBestseller No. 5
BLCKTEC 430 Bluetooth OBD2 Scanner Diagnostic Tool - Car Code Reader for All Cars OBDII Compatible - Read & Clear Engine, ABS, SRS, Oil Light, & More - Subscription Free OBD App On iOS & Android
  • SIMPLIFYING CAR REPAIR - Our goal is to simplify your car repair process. Our device turns your smartphone into a powerful OBD2 scanner diagnostic tool, allowing you to quickly understand your vehicle's problem, view recommended fixes, and purchase the necessary parts for repair.
  • EXPERIENCE PROFESSIONAL DIAGNOSTICS - BLCKTEC's enhanced vehicle diagnostics gives you access to advanced features typically found only on high-end scanners. With our car code reader you can read and clear engine codes, ABS (brakes), SRS (airbags), TPMS codes, and many more.
  • RELIABLE AND ACCURATE RESULTS - Our car scanner utilizes the latest OBD2 technology to provide accurate and reliable diagnostic information, ensuring that you can trust the results you receive.
  • COMPATIBLE WITH A WIDE RANGE OF VEHICLES - Our bluetooth OBD2 scanner works with most vehicles made after 1996, including cars, trucks, and SUVs, making it a versatile tool for any DIYer.
  • USER-FRIENDLY APP - Our accompanying app is easy to use and navigate, with clear and concise information displayed in an easy-to-understand format. Available on IOS and Android.
SaleBestseller No. 6
LAUNCH CRP123 OBD2 Scanner 2024 Newest Elite Code Reader Engine/ABS/SRS/Transmission Car Diagnostic Tool, ABS Code Reader, SRS Scan Tool, Check Engine Code Reader, Lifetime Free Update Scan Tool
  • 🎁 New Elite Version🎁 Easy to Use--Work out of Box🎁Function as LAUNCH CRP123E 🎁 Lifetime Update🎁 5 YEARS Back Up.
  • [Engine/ABS/SRS/Transmission Diagnostic Tool]----The crp123 obd2 scanner is perfect balance of power and affordability, providing the ability to view preset, or user defined, live data streams for ENGINE, AT, ABS and SRS data, the ability to graph, record, replay and print data, read and resets codes for engine/abs/srs/transmission system.(Note: Does not work for other System and does not have Special services!)
  • [Full OBDII Test Code Reader]----LAUNCH CRP123 scan tool supports all 10 modes of OBDII standard to ensure complete, accurate, system diagnosis. Read and Clear DTCs, do smog tests , I/M readiness and O2 sensor tests, Mode 06 EVAP system test, Mode 08 on-board test component test. And OBDII Code lookup tool and acronym database to assist and speed diagnosis and repair time.
  • [Live Data Stream + Advanced OBDII Scanner + Lifetime Update]---- Launch crp123 scanner support for Generic OBDII Codes (P0, P2, P3 and U0); manufacturer specific codes (P1, P3 and U1); pending codes; freeze frame data; monitor and I/M readiness; live PCM stream data; graphing functionality for up to four (4) live data streams include the Engine Coolant Temperature, Long&Short Fuel Trim, the change of Accelerator Pedal Position Sensor , Throttle valve position , Generator load signal,Fuel Tank Pressure , Engine RPM, Intake Ait Temperature and so on; clears DTC codes and turns off the MIL; resets monitors; provides Data Link Connector (DLC) location hints.
  • [Extensive Vehicle Coverage + 10 Languages]--The LAUNCH CRP123 reads data from ENGINE, TRANSMISSION, ABS and SRS systems from Asian, US and European manufacturers. Coverage includes for Suzuki, for Honda, for Mitsubishi, for Nissan, for Toyota,for Mazda, for Hyundai,for Kia, for Subaru,for Infiniti, for Lexus, for Acura, for Isuzu, for Ford, for GM, for Chrysler, for Benz, for BMW, for VW, for Opel, for Volvo, for Fiat,for Land Rover, for Seat, for Skoda, for Audi,for Porsche, for Saab, for Jaguar and many others. Support 10 different languages.
SaleBestseller No. 7
BlueDriver Bluetooth Pro OBDII Scan Tool for iPhone & Android
  • [Pro OBD2 Scanner] - BlueDriver is the easiest way to scan and understand your vehicle like a professional mechanic. Read and clear your car’s trouble codes and check engine light.
  • [Read & Clear All The Codes] - BlueDriver's enhanced vehicle diagnostics gives you access to information normally available only to mechanics on their OBD2 scan tools. Now you can read and clear ABS, Airbag, SRS, TPMS codes, and many more.
  • [Get The Right Fix] - Much more than a car code reader, BlueDriver is a diagnostic tool. Get unlimited specific repair reports containing possible causes, reported fixes, and more for virtually every vehicle make and model.
  • [Wireless & Bluetooth Enabled] - Say goodbye to wires. BlueDriver connects with Bluetooth via your phone/tablet to a sensor that plugs into your car's OBDII port. Get all of the capabilities of an expensive code reader & scan tool without any annoying wires.
  • [User-Friendly App and Repair Videos] - BlueDriver gives you more ways to scan and fix your vehicle. Our iOS & Android app connects you to a large database of repair videos with step-by-step directions of repairs.
Bestseller No. 8
ANCEL FX2000 OBD2 Scanner Diagnostic Tool, ABS SRS Transmission Airbag Car Scanner, Check Engine Car Code Reader, Automotive Scan Tool for All Cars
  • 🔧【PLUG AND PLAY - EASY TO USE】 : ANCEL FX2000 car scanner only takes 3 steps to connect to the car for diagnosis without cumbersome operations. The latest FX2000 scan tool is equipped with a one-key diagnosis function, which can automatically identify the model and year of your car, and automatically diagnose the car. Even beginners can use it to read the data and find out what the fault codes mean.
  • 🚗【FULL OBD-LEVEL DIAGNOSTICS TOOL】: Quickly determines the cause of engine system faults, reads current, permanent and pending codes. After the repair, clears the codes and turns off the warning light. In addition, the FX2000 engine code reader also displays important OBD II advanced data such as fuel, live data and other manufacturer-specific parameters in real time to ensure that the engine ECU is operating correctly and safely, saving vehicle owners a lot of time and money in maintenance.
  • 🚙【TRANSMISSION FAULT DIAGNOSTIC TOOL】: Some noises come from the transmission? Ancel obd2 scanner will read fault codes, display live transmission system data (fluid temperature, fluid pump, clutch actuation, pressure, etc.), and ensures transmission performance is optimal for vehicle speed and load. It provides detailed TCM data of the vehicle, so you can quickly and accurately find existing or potential problems.
  • 🚐【FIND OUT SRS WRONG】: ANCEL FX2000 automotive scanner is able to read and clear fault codes in the SRS (airbag) and turn off the warning light to make sure the system is working correctly and safely. This odb2 scanner also displays a live graphical data stream of the supplemental restraint system (air bag), which allows you to analyze and verify that the air bag system is working properly.
  • 🚌【ABS OBD2 SCANNER】:The FX2000 diagnostic scanner for all vehicles can read and clear the Diagnostic Trouble Codes (DTC) data stream transmitted from the ABS. By retrieving the ABS code data, the obd scanner can check the various brake components and accurately diagnose problems.
Bestseller No. 9
OBD2 Scanner TOPDON AL600, ABS SRS Code Reader, Diagnostic Scan Tool, Active Test for ABS/SRS, with Car Maintenance Reset Service of Oil, BMS, SAS
  • ABS/SRS OBD2 Scanner > Enjoy this ABS OBD2 code reader to reveal exact issues underlying in your brake, airbag, and engine systems, test individual ABS/SRS sensors, valves, or solenoids to quickly locate malfunctions (compatible with GM, Nissan, Fiat, Benz, Volvo, Land Rover, BMW, USA Ford, please reach us for details.), making sure critical safety systems work in perfect harmony together against accidents to be safe than sorry. NOTE: Only support upgrade on windows.
  • 3 Most Needed Service Functions > This OBD2 scanner guides you through step by step procedures to reset oil service light and programmed mileage intervals for engine efficiency (Oil Reset); to calibrate steering wheel position for vehicle’s traveling in a straight line (SAS Reset); to clear the original low battery fault information against coming battery failures or damage (BMS Reset); saving your needless visits to mechanics. NOTE: Not suitable for all models, please reach us for compatibility.
  • Full OBD2 Diagnostics > Say goodbye to the hassle of manual check-ups via this srs code reader. Quickly correct Check Engine Light warning on most OBD2/CAN compatible vehicles. Easily access to your smog status with one simple click I/M Readiness; and being filled with features for live data readings, freeze frame data, plus EVAP system, onboard monitor test means this scan tool checks all daily car care boxes.
  • Work Easier > Red-Yellow-Green LEDs in this OBD2 scanner quickly show the overall DTC status without toggling through menu selections. HELP hotkey takes you directly to detailed descriptions/tips. Read/Erase DTC, I/M readiness shortcuts are added for optimized operation, along with DTC Lookup library for interpreting codes, designing the SRS OBD2 code reader a pleasure to use right out of the package even for beginners.
  • Helpful Service > Get instant, free lifetime access to the most recent updates to add new car models and troubleshooting bugs making the OBD2 scanner a long-term investment for any home mechanics. The extended 1 years of quality assurance sweetens the worry-free deal even further. Multilingual Menu: EN, FR, ES, DE, IT, RU, PT, and JP. NOTE: Only support upgrade on windows.
Bestseller No. 10
OBD2 Scanner Diagnostic Tool, Code Reader LAUN CH CR529, 2024 ABS SRS Scan Tool, check engine light scanner, OBD2 Scanner car code reader, full OBDⅡ Modes, Read/Clear Codes, 5 yrs warran.,fr-ee update
  • Check Engine Light Killer ➤ Annoying engine error light keeps popping out? No frustrating. LAUN CH CR529 is born to kill the Check Engine Light on your dashboard. This obd2 scanner can clear the trouble codes in seconds, save you a bundle in unwanted repair cost, and help you make the proper repairs without any guess work.
  • Patented One-Click Smog Checker ➤ How effective this scan tool is? You will be completely blown away. With just one press of a button to run a quick check, you’ll see if the car is ready to pass the emission test, without the hassle of driving around endlessly, or continuously coming back to the repair shop for retest.
  • Effective Car Status Analyzer ➤ Want to get educated enough before hitting the dealer? Live Data shows clearly and vividly in graphical way, being super easy for you to ensure if the data are in normal conditions / ranges, or not. Red-Yellow-Green LEDs indicate vehicle’s status visually, to avoid unnecessary step-to-step operations.
  • Wide-Ranging Cars Supporter ➤ Doubt about the compatibility? The diagnostic scanner can be used regardless of the type of your vehicle, as long as it is OBD2 compliant (1996 and newer): KWP2000, ISO9141, J1850 VPW, J1850 PWM and CAN. Multiple language option is also packed: English, French, Spanish, German, Portuguese, Russian, Japanese.
  • A Necessity in Toolbox ➤ Classic and solid design to withstand everyday shocks; HELP shortcut key for quick access to commonly tips; Plug & Play, no battery required; AutoVin, DTC LookUp, Data Playback and Print etc. Whether you’re a home car owner or an auto mechanic, with CR529, you can save thousands of dollars on car maintenance, save time and effort on repairs, and dramatically improve your car’s lifespan / performance.

Last update on 2024-02-13 / Affiliate links / Images from Amazon Product Advertising API

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