2021 Alfa Romeo Stelvio

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 ChryslereBay logo (FCA US, LLC)

Components SERVICE BRAKES, HYDRAULIC, SERVICE BRAKES, AIR

Potential Number of Units Affected 9

 

Summary

ChryslereBay logo (FCA US, LLC) is recalling certain 2019-2021 Alfa RomeoeBay logo Stelvio and 2020-2021 Alfa RomeoeBay logo 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 RomeoeBay logo Giulia and 2019 through 2021 Model Year (GU) Alfa RomeoeBay logo 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 RomeoeBay logo Giulia
2019 – 2021(GU)Alfa RomeoeBay logo 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 [email protected] 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 IIeBay logo
  • 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 RomeoeBay logo 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 HP280 HP
MINMAXMINMAX
FL (mm3)1440255014952755
FR volume (mm3)1625273517903050
RR volume (mm3)87019908701990
RL volume (mm3)85519758551975

 

  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 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.

 

B. (GA) Alfa RomeoeBay logo 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
MINMAXMINMAX
FL (mm3)1450256019003110
FR volume (mm3)1580269021903400
RR volume (mm3)83019207501840
RL volume (mm3)81519057351825

 

  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 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.

 

C. (GU) Alfa RomeoeBay logo 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)14952755
FR volume (mm3)17903050
RR volume (mm3)8701990
RL volume (mm3)8551975

 

  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

MAKEMODELYEAR
ALFA ROMEOGIULIA2020-2021
ALFA ROMEOSTELVIO2019-2021

 

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


⬇ Download PDF (97.73 KB)

 

Recall Quarterly Report #1, 2021-2

RCLQRT-21V309-3414.PDF 211.147KB


⬇ Download PDF (206.2 KB)

 

Defect Notice 573 Report

RCLRPT-21V309-3256.PDF 215.383KB


⬇ Download PDF (210.33 KB)

 

ISSUED Interim Owner Notification Letter(Part 577)

RIONL-21V309-0140.pdf 303.485KB


⬇ Download PDF (296.37 KB)

 

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


⬇ Download PDF (94.23 KB)

 

ISSUED Owner Notification Letter(Part 577)

RCONL-21V309-2558.pdf 515.382KB


⬇ Download PDF (503.3 KB)

 

Recall Acknowledgement

RCAK-21V309-8458.pdf 645.263KB


⬇ Download PDF (630.14 KB)

 

Remedy Instructions and TSB

RCRIT-21V309-0432.pdf 3122.299KB


⬇ Download PDF (2.98 MB)

 

Recall Quarterly Report #2, 2021-3

RCLQRT-21V309-5207.PDF 211.241KB


⬇ Download PDF (206.29 KB)

 

Remedy Instructions and TSB

RCRIT-21V309-5490.pdf 3110.122KB


⬇ Download PDF (2.97 MB)

 

ISSUED Renotification Notice

RCRN-21V309-1412.pdf 772.396KB


⬇ Download PDF (754.29 KB)

 

Recall Quarterly Report #3, 2021-4

RCLQRT-21V309-1264.PDF 211.32KB


⬇ Download PDF (206.37 KB)

 

Latest Recalls Documents

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

 

 

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  • [Affordable] + [Reliable Car Health Monitor] Will you be confused what happens 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. Note：The device is a diagnostic tool, not a repair tool. To turn off a warning light, you must first physically repair the issue causing it. Only then can the scanner be used to clear the corresponding fault code.
  • [5 in 1 Car Diagnostic Scanner] Compared with obd scanners (50-100), NT604 Elite code scanner not only includes their OBDII diagnosis but also serves as 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. Note: doesn't support maintenance functions like reset or relearn. For the SRS system, NT604 Elite can read and clear common fault codes not caused by a crash, but crash/collision data cannot be cleared.
  • [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 brands from worldwide (America/Asia/Europe). You don’t need to pay extra software fee. AUTOVIN may not work on some older vehicles or certain vehicle brands. If AUTOVIN fails, please input the vin code manually or go to the Diagnostic Menu to select your vehicle model.
  • [Solid protective case KO plastic carrying bag] + [Lifetime update] Almost all same price-level car scanner diagnostic tool only offers plastic bag to hold 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.
$169.99 −$34.03 $135.96
Buy on Amazon Price incl. tax, excl. shipping
SaleBestseller No. 2
OBDMATE OBD2 Scanner with ABS SRS Transmission, Reset Fault Lights | Check Engine Code Reader with Full OBDII Functions | DLC Pin Test | Battery Voltage Check, Car Diagnostic Tool
OBDMATE OBD2 Scanner with ABS SRS Transmission, Reset Fault Lights | Check Engine Code Reader with Full OBDII Functions | DLC Pin Test | Battery Voltage Check, Car Diagnostic Tool
  • 【Reset ABS/SRS/Transmission/Engine Lights】 More than an check engine code reader, OBDMATE OM901 obd2 scanner performs comprehensive diagnostics for the 4 most-used systems (ABS/SRS/Engine/Transmission). It quickly clears fault codes, turns off warning lights, read data stream and auto VIN.
  • 【3.5" Handheld Scanner with 4 System Diagnose】 3.5" Super large TFT screen equipped displays an intuitive menu and clear readings of various sensors from ABS, SRS, ECM and TCM systems. It arrived with a silicone protective case and hard-shell carrying case, ensuring long-lived durability and drop resistance. The car diagnostic tool is plug-to-play designed, plug it and get diagnosis started without any batteries or updates required.
  • 【One-Click I/M Readines&Full OBD2 Functions】 Press F1 to get an intuitive corloured form about whether various emissions-related systems on the vehicle are operating properly. Help you get smog-check ready quickly. OM901 car scanner supports all essential OBD2 functions you need: read & clear codes, view freeze frame, read I/M readiness, retrieve VIN, live data stream (with graphing display), O2 sensor test, onboard monitoring mode, and EVAP leak test.
  • 【Battery Voltage Check&DLC Pin Test】 It allows you to monitor battery health by monitoring current battery voltage. Plus, this obd2 diagnostic tool features DLC 16-PIN test to check current voltage of every pin.
  • 【Automotive Scanner Diagnostic Kit】 The package comes with 1 car scanner, 1 USB-type c cable, 1 hard storage bag and 1 user manual(en). Free to update without any hidden fees. 5 languanges available in setting including English, French, Italian, German and Espanish. Valuable and Portable, making it a great tool kit for car owners, DIY enthusiasts, and professional mechanics.
$139.99 −$30.00 $109.99
Buy on Amazon Price incl. tax, excl. shipping
SaleBestseller No. 3
BlueDriver Pro Next Gen OBD2 Scanner – No Subscription, Bluetooth Car Code Reader for iPhone & Android – Diagnose 8000+ Issues, ABS SRS TPMS, Repair Reports, Vehicles 1996+
BlueDriver Pro Next Gen OBD2 Scanner – No Subscription, Bluetooth Car Code Reader for iPhone & Android – Diagnose 8000+ Issues, ABS SRS TPMS, Repair Reports, Vehicles 1996+
  • [Diagnose Like a Pro] BlueDriver Pro Next-Gen is a professional OBD2 scanner and diagnostic tool that helps you scan, understand, and clear vehicle trouble codes with confidence. Turn your phone into a powerful car diagnostic scanner—no guesswork, no unnecessary repairs.
  • [Read and Clear More Codes Than Ever] Read and clear more codes than basic car code readers. Access enhanced diagnostics for Check Engine, ABS, SRS, Airbag, TPMS, Transmission, and more on supported vehicles, including expanded coverage on newer model years.
  • [Verified Fixes and Real-Time Data] Get unlimited, technician-verified repair reports matched to your VIN, with definitions, causes, and confirmed fixes. Monitor live vehicle data as you drive, view freeze frames, check smog readiness, and analyze Mode 6 test results.
  • [Expanded Make & Model Coverage] Optimized for today’s vehicles with strong support for GM, Ford, Stellantis (RAMeBay logo, JeepeBay logo, Chrysler), Toyota, Honda, Nissan, Mazda, Subaru, Hyundai, Mercedes-BenzeBay logo, BMW, and VW. Enhanced communication on select 2024+ Nissan and Mazda models (see compatibility chart).
  • [Gas Vehicles 1996+ & Select Light-Duty Trucks] Works with all gas-powered vehicles made in 1996 or newer, plus select light-duty trucks and diesels, including F-250, RAMeBay logo 2500, Silverado, and Sierra. Built for daily drivers, family vehicles, and real-world truck use.
$129.95 −$35.00 $94.95
Buy on Amazon Price incl. tax, excl. shipping
SaleBestseller No. 4
FOXWELL NT614 Elite OBD2 Scanner for DIY Mechanics, Upgrade of NT604, 4 System Diagnostic Tool with 5 Resets (ABS Bleeding, EPB, Oil, SAS, Throttle), Read/Clear Engine/ABS/SRS/Transmission Fault Codes
FOXWELL NT614 Elite OBD2 Scanner for DIY Mechanics, Upgrade of NT604, 4 System Diagnostic Tool with 5 Resets (ABS Bleeding, EPB, Oil, SAS, Throttle), Read/Clear Engine/ABS/SRS/Transmission Fault Codes
  • PAID FOR ITSELF ON FIRST USE - SAVE ON EVERY DIAGNOSIS: Avoid expensive shop fees and take control of vehicle repairs at home. The NT614 Elite delivers professional-level diagnostics for Engine, ABS, SRS Airbag, and Transmission systems, helping you quickly identify the real cause of warning lights and avoid unnecessary repairs. With 5 essential service resets including Oil Reset, EPB, ABS Bleeding, SAS Calibration, and Throttle Relearn, you can complete everyday maintenance and repairs without paying dealership visit. Features WiFi updates, no registration required, and plug-and-play setup with no extra power cord
  • 5 ESSENTIAL RESETS FOR REAL DIY MAINTENANCE: More than just a diagnostic tool, the NT614 Elite gives you the service functions DIYers actually need to avoid expensive shop visits. Perform Oil Reset, EPB brake service, ABS bleeding, steering angle calibration, and throttle relearn to fix common maintenance issues at home with confidence. Reset warning lights, replace brake pads, restore throttle performance, and complete essential maintenance without paying dealership labor costs. Note: Function availability varies by vehicle make, model, year, engine type, and system configuration. Please confirm compatibility before purchase.
  • SAME 4-SYSTEM DIAGNOSTICS AS NT604: Built on the trusted NT604, the NT614 Elite delivers full diagnostics for Engine, ABS, SRS Airbag, and Transmission systems-helping you identify the root cause behind warning lights instead of guessing. Read and clear codes, view live data graphs, monitor engine temperature, wheel speed sensors, transmission temperature, and more for accurate troubleshooting at home
  • LIVE DATA GRAPHING - FIND PROBLEMS BEFORE THEY GET EXPENSIVE: See what basic scanners miss with real-time data displayed in easy-to-read graphs. Monitor fuel trims, oxygen sensors, engine load, RPM, battery voltage, and transmission temperature to detect intermittent or hidden problems before they become costly repairs. Diagnose faster and make smarter repair decisions with visual data insights
  • AUTO VIN + LIFETIME WI-FI UPDATES + WIDE COVERAGE: AutoVIN instantly identifies your vehicle for faster setup and fewer errors. Generate professional vehicle health reports for maintenance tracking, used car inspections, or sharing with mechanics. Stay updated with lifetime free Wi-Fi updates-no subscriptions or hidden fees. Supports 90+ brands and 10,000+ models including Ford, Toyota, BMW, Mercedes-BenzeBay logo, Honda, Nissan, Volkswagen, Hyundai, Subaru, and more for long-term reliable use
$189.99 −$34.00 $155.99 Amazon Prime
Buy on Amazon Price incl. tax, excl. shipping
SaleBestseller No. 5
BLCKTEC 460T OBD2 Scanner Car Code Reader Engine ABS SRS Transmission Diagnostic Tool, 12 Reset Services, Oil/TPMS/EPB/BMS/SAS/DPF/Throttle Reset, ABS Bleeding, Battery Test, Auto VIN, Free Update
BLCKTEC 460T OBD2 Scanner Car Code Reader Engine ABS SRS Transmission Diagnostic Tool, 12 Reset Services, Oil/TPMS/EPB/BMS/SAS/DPF/Throttle Reset, ABS Bleeding, Battery Test, Auto VIN, Free Update
  • [All System Diagnostics, Professional-Level Scanner] - BLCKTEC 460T is the ultimate OBD2 diagnostic tool for home mechanics and professionals. It supports all 10 OBD2 modes, reads and clears Engine/Transmission/ABS/SRS codes, performs All-System Diagnostics, offers workshop reset tools, and provides real-time live data. It helps you pinpoint issues, assess your car's condition, and prepare for SMOG checks with ease. NOTE: Function availability depends on your vehicle. Before you buy, be sure to use the Compatibility Checker on BLCKTEC website or contact our customer support to verify that the features you need are supported for your vehicle’s specific year, make, and model.
  • [12+ Most Popular Reset Functions] - BLCKTEC 460T OBD2 scanner offers 12+ dealer-level service functions, including Oil Maintenance Reset, ABS Bleeding, EPB Reset, SAS(Steering Angle Sensor) Recalibration, DPF(Diesel Particulate Filter) Reset, Throttle Body Relearn, Battery Reset/Initialization, TPMS Relearn, Transmission Reset, Fluid Change Reset, Maintenance Reset and more, enabling you to perform workshop services like a pro. NOTE: Function availability depends on your vehicle. Be sure to use the Compatibility Checker on BLCKTEC website to verify that the features you need are supported for your vehicle.
  • [Real-Time OBD2 and OEM Live Data, Freeze Frame Data] - BLCKTEC 460T helps diagnose vehicle issues when warning lights like Check Engine Light or ABS/SRS Light appear. It offers detailed DTC info, ECU Freeze Frame Data, and real-time OBD2 and advanced OEM live data, including Engine, Transmission, ABS, SRS, and more, making it easy to diagnose and resolve vehicle problems. You can view, graph, record, replay, and overlay up to four live data streams in a single graph for better analysis.
  • [AutoVIN, AutoReLink, AutoScan, 3X Faster] - Equipped with AutoVIN technology, 460T automatically retrieves the VIN to save you time. Its AutoScan and AutoReLink features scan all of the vehicle's ECUs and detect any fault codes immediately after you plug the scanner into the vehicle's OBD2 port - no button presses required. Additionally, it regathers DTC and I/M readiness information every 30 seconds, simplifying monitor tests. 460T's advanced technology makes it 3X faster than other products.
  • [Get RepairSolutions2, the #1 Auto Repair App for Free] - When paired with RepairSolutions2(RS2) App, 460T becomes even more powerful. RS2's Verified Fix Database built by master technicians, provides the parts needed for the repair. Additionally, RS2 gives you access to OEM warranty info, maintenance schedules, TSB, and dealership recall info, making car care easier than ever. RS2 is free with no subscription fees and it stores your car scan reports in the cloud, allowing you to access, share, or print them anytime and anywhere.
$249.99 −$50.00 $199.99
Buy on Amazon Price incl. tax, excl. shipping

Last update on 2026-06-15 / Affiliate links / Images from Amazon Product Advertising API

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