te.se.o. newsletter – no. 10/10 -...

Mirafiori, 27/09/2010

Te.Se.O. Newsletter – No. 10/10

What is Te.Se.O.? Te.Se.O. (Technical Service Operation) is the technical body for Customer Services – Technical Services. The function of Te.Se.O. is to provide technical/diagnosis support to both authorised and independent Dealerships when product faults are identified after sale in the cases listed below. Starting from 1st January 2008, the services offered by Te.Se.O. are given free of charge in the following cases: (i) cases regarding FGA cars under contractual or extended warranty (ii) when a subscription to the technical documentation is effective at the time of contacting Te.Se.O. (iii) following a report by a Dealer Expert Technician (DET.), level 1, either certified or being certified by FGA according to the training program of the Training Academy and (iv) limited to European Union Countries. To the benefit of the Authorised and Independent Dealerships, and on a test basis, the free-of-charge support provided by Te.Se.O. is also temporarily extended to all those vehicles under 10 years old whose contractual or extended warranty (see item "i") has expired. What is the newsletter? It is a preliminary technical investigation relating to specific reported faults about the product irrespective of contractual warranty expiry. The structural elements of the Newsletter are: Vehicle data (MVS, engine version, chassis group - if any) Customer's reported fault Result of workshop analysis Operation What is it used for? The Newsletter is used to certify a specific Customer's reported fault and provide standard technical and conduct guidelines to Dealerships and Customers. Homogeneity of the technical problem, based on a clear diagnosis track, reduces repeated service interventions that do not find a permanent solution to the fault.

Copyright © by Fiat Group Automobiles S. p. A 1

How is it used? The document provides a technical "cycle" that gives service recommendations for each reported fault until official service solutions are issued. It therefore provides field operators with standard information and can be used by technical workshop personnel for correct technical management of the serviced chassis. The updating is part of product improvement. If you need to contact Te.Se.O. follow the instructions provided in the section “What is Te.Se.O.?" and check the method of contact (electronic ticket or fax) for the country as well as the type of workshop making the request. NOTE: remember that when making explicit reference to Tutorship, the reports must be sent through the appropriate eSIGI channel, whereas in Countries where they are not present, draft a TK for the Te.Se.O. of your Market, according to the standard procedure.

Sheet Model Subject Release date

Date of last update

Closing date Notes

12e Various models

Engine warning light switching-on and poor performance 22/06/07

14 Various models

Injector IMA code writing procedure using Examiner 21/03/08

15e 147-159 Cold start-up takes longer than 3 seconds 21/03/08 05/09/08

18ts 159 Main beam headlights not working 28/05/08

19ts 159 Rear screen wipers not working 27/06/08 21e 159 Gearshifting lever vibration 17/07/08 22 MiTo Seat belt locking 05/09/08 23 MiTo Brake screeching 24/04/09

24ts Various models Blue&Me - Blue&Me nav 24/04/09 18/12/2009 Table

modified 25 159 Steering noise 25/09/09

26 MiTo Missed operation/irregular operation of electrical components

09/12/09

27 Various models

Occasional white smoke from the front area 18/12/09

28 Various models

Models with Start&Stop Error P0555. 29/01/10 10/03/2010

29 Various models

Switching off when idling with LPG supply engaged. 24/02/10

30 Various models Radio Nav. system failure 23/04/10 27/09/10

Issued S.N. 55.04.10 for

MiTo 55.11.10 for

159-Brera/Spider

31 Various models

The engine does not perform/does not start 23/04/10

32 Alfa Spider Soft top malfunctioning 23/04/10


33 MiTo Missed switching off of seat belt buzzer 21/05/10 18/06/10

34 MiTo Steering wheel centring 18/06/10

35 MiTo Manual climate control system knobs 22/07/10

36 Giulietta Failed operation of the dusk sensor 22/07/10

37 Giulietta Missed PROXI alignment 22/07/10 38 MiTo Excessive oil consumption 03/09/2010

39 Various models EOBD warning light switching on 27/09/10



Copyright © by Fiat Group Automobiles S. p. A

4

Sheet 12e – Various models VERSIONS 2.2 JTS 159 – Brera – Spider 1.9 JTS 159 CUSTOMER'S REPORTED FAULT Engine warning light switching-on and poor performance RESULT OF WORKSHOP ANALYSIS Detected errors of variable timing system (errors P0010-P0011-P0013-P0014-P0016-P0017) OPERATION Once the customer's reported fault is confirmed, carry out following checks/inspections:

1) Disconnect the solenoids from engine wiring and trigger them externally with short pulses through the connection of a battery.

2) If the faults persist, disconnect the solenoids and check whether the filters are dirty. If filters are dirty clean them with compressed air and/or petrol, then trigger them externally with short pulses through the connection of a battery.

3) If the faults persist replace the concerned solenoid/s. 4) If the faults persist check the engine timing and the correct positioning of the toothed

wheels on the camshafts. 5) If the faults still persist replace the phase transformers.

If the customer's reported fault persists, contact Te.Se.O. and attach the relevant diagnosis documentation to the Ticket in Dealership


Date of last update

Closing date Notes

12e Various models

Engine warning light switching-on and poor performance 22/06/07



5

Sheet 14 – Various models VERSIONS All models with 1.9 - 2.4 Mjt engines and EDC16C39 engine management control unit

Injector IMA code writing procedure using Examiner OPERATION After the injectors and/or engine management control unit replacement, during the IMA code writing phase using Examiner proceed as follows:

• Write the IMA codes directly from the injectors • Place the key on STOP (key-off) position • Wait for the power latch (control unit deactivation delay) end; the operation takes a couple

of minutes on average • Place the key on MAR (key-on) position • Use Examiner to check the correct injector IMA code by reading the injector codes and

visually checking the injectors If this procedure is not followed, the IMA code is recorded in the EEPROM memory of the engine control unit but the self-learning parameters of the injector flow are not adjusted. This can cause irregular engine function (knock, wrong corrections). The INCOMPLETE procedure on Examiner currently operates as follows:

1) write a 9-figure alphanumeric code and press CONTINUE


Date of last update

Closing date Notes

14 Page 1/2

Various models




6

2) Writing in progress

If the writing is successful, the Examiner returns to the active diagnosis screen without prompting to place the key on STOP position, to wait for the power latch end and then to place the key on MAR.


Date of last update

Closing date Notes

14 Page 2/2

Various models




7

Sheet 15e - Alfa 147 - 159 VERSIONS 1.9 JTD 8v CUSTOMER'S REPORTED FAULT Cold start-up takes longer than 3 seconds RESULT OF WORKSHOP ANALYSIS Customer's reported fault confirmed OPERATION

• Check the diesel filter • Check the fuel supply system • Check the battery efficiency • Check the alternator charge • Check the earth resistance between the battery/body/engine • Check engine absorption at start-up using ammeter pliers. • Check cylinder compression when cold • Check that the part number of injectors and spark plugs is the same as that reported below:

POWER BOSCH SPARK PLUG PART NO.

FPT SPARK PLUG PART NO.

FPT INJECTOR PART NO.

105 HP 0250202036 46754154 55192579 120 HP 0250202132 55200817 55200259

If the concerned part numbers do not match those mentioned above, replace the above mentioned components. If the customer's reported fault persists, contact Te.Se.O. Do not carry out any interventions and/or replacements.


Date of last update

Closing date Notes

15e 147-159 Cold start-up takes longer than 3

seconds 21/03/07 05/09/08



8

Sheet 18ts Alfa 159 VERSIONS All versions that are not subjected to Tutorship. CUSTOMER'S REPORTED FAULT Main beam headlights not working RESULT OF WORKSHOP ANALYSIS Customer's reported fault confirmed OPERATION Once the customer's reported fault has been confirmed, perform the below mentioned inspections/controls to verify the correct functionality of the steering column stalk:

Step Control Ok Ko

1 Check the condition of the main beam headlight protection fuses and of the bulbs

Move on to step 2

2

Disconnect the female connectors attached to male connector seats "A" and "B" of the steering column stalk: check for any possible loose contact, incomplete connections, terminals that are poorly seemed, loose or inverted. (fig. 1)

Move on to step 3

Repair any faults, reconnect the female connectors "A" and "B" to the steering column stalk seat and check that they are working correctly. If the fault does not disappear move on to step 2


Date of last update

Closing date Notes

18ts Page 1/5 159 Main beam headlights not working

28/05/08



9

3

Identify output 7 on female connector "A" and output 4 on female connector "B". Shunt them after turning on the panel. Once the described operation is performed, each time the jumper is connected the main beam headlight must switch on in flasher mode. When the jumper is disconnected, the headlight should switch off.

Move on to step 4

Replace the steering column stalk.

4

Repeat the operation between output 7 of female connector "A" and output 3 of female connector "B". When the jumper is connected, the main beam headlight must switch on but in this case the light must not change its status even when the jumper is disconnected. The status only changes when the jumper engages again (fig. 2)

Move on to step 5



Date of last update

Closing date Notes


28/05/08



10

5

Remove the stalk from steering column. Position an ohmmeter (set to the low full scale) between pin 7 of connector "A" on the steering column stalk and pin 4 of connector "B" of the steering column stalk. Make sure that the stalk is in its rest position. (Note: if it is present, use pin 9 of connector "B" instead of pin 7 of connector "A"). The ohmmeter should show an almost infinite resistance or at least in the order of tens of Mega Ω. Leaving the ohmmeter connected, bring the stalk to the headlamp flasher position (1st click). When the stalk is in this position the resistance should immediately fall to a value of between zero and a maximum of 30 Ω. Note: the prescribed value should be the net resistance of the measuring system used (ohmmeter, cables, prods etc). Releasing the lever should return the resistance to close to infinite or in the order of tens of Mega Ω (fig. 3)

Move on to step 6

Replace the steering column stalk

6

Repeat the operation between output 7 of connector "A" and output 3 of connector "B": at the first click of the stalk (flasher), the circuit should remain open while bringing the steering column stalk to the main beam position (2nd click) should give a maximum ohmmeter reading of 30 Ω. Releasing the stalk should return the resistance to close to infinite or in the order of tens of Mega ohm. (Note: if it is present, use pin 9 of connector "B" instead of pin 7 of connector "A"). (fig. 3)

Contact Te.Se.O.

Replace the steering column stalk


Date of last update

Closing date Notes


28/05/08



11

Fig. 1

A B

Cruise Ctrl.

Fig. 2 connector A connector B


Date of last update

Closing date Notes


28/05/08

43

7



12

Fig. 3 Connector A location on steering column stalk

Connector B location on steering column stalk

If the customer's reported fault persists, contact Te.Se.O. Do not carry out any interventions and/or replacements.


Date of last update

Closing date Notes


28/05/08



13

Sheet 19ts – Alfa 159 VERSIONS All models that are not subjected to Tutorship CUSTOMER'S REPORTED FAULT Rear screen wipers not working RESULT OF WORKSHOP ANALYSIS Customer's reported fault confirmed OPERATION Once the customer's reported fault has been confirmed, perform the below mentioned inspections/controls to verify the correct functionality of the steering column stalk, following the instructions in the table. Preliminary operations Check the rear screen wiper protection fuse and replace it if necessary. Check that the system is working correctly. If the reported fault is that the rear window wiper is not working, proceed as indicated in table 1. If the reported fault is that the rear window wiper arm does not go back to the rest position, proceed as indicated in table 2.


Date of last update

Closing date Notes

19ts Page 1/4 159 Rear screen wipers not working

27/06/08



14

TABLE 1

Step Control Ok Ko

1

Disconnect the female connector attached to the "B" male connector seat of the steering column stalk: check for any possible loose contact, incomplete connections, terminals that are poorly seemed, loose or inverted. Then proceed to the correct reconnection of the female connector "B" to the seat of the steering column stalk. Fig. 1

Move on to step 2

Repair any faults, reconnect the connectors and check that they are working correctly. If the failure persists, move on to Step 2.

2

Remove the female connector "B" only. The rear window wiper must be turned off and the wiper at rest. Identify outputs 1 and 12 on female connector "B" and shunt them after turning on the panel. By performing the operation described above, the rear window wiper must start its travel until the outputs are shunted; if the jumpers are removed the wiper must immediately interrupt its travel. Fig. 2

Replace the steering column

stalk.

If the rear window wiper does not move, check the

motor and the electric system between the steering column stalk connector and

the motor.


Date of last update

Closing date Notes


27/06/08



15

TABLE 2

Step Control Ok Ko

If the motor does not start, replace the steering column

stalk

1

Shunt outputs 1 and 12 of the female connector again and stop the wiper halfway across the rear window by disconnecting the jumper. With the wiper stopped halfway on the rear window: - switch the panel off - make sure that the windscreen wiper control lever in the steering column stalk is in the OFF position (completely off) - reconnect the connector "B" to the steering column stalk. - switch the panel on again. When these operations are carried out, the wiper should return to the rest position and stop. Fig. 2

Other type of fault, contact

Te.Se.O. for a possible technical

support.

If the motor starts again but does not stop, move on to

step 2

2

Remove the stalk from the steering column and reconnect connectors "A" and "B" to the steering column stalk. - Access the terminals at the back of the female connector "B" by removing the rear plastic protection of the connector - Turn on the panel with the rear window wiper control ring nut on OFF position. At this point, the rear window wiper should spontaneously begin to move. - After the first wiper stroke, shunt contact 2 of the female connector "B" to earth. The wiper must stop immediately and only start again when the jumper is removed. Fig. 3

Check the rear window wiper motor and the electric system

from the motor to the steering

column stalk.



Date of last update

Closing date Notes


27/06/08



16

Fig. 1

A B

Cruise Ctrl.

Fig. 2 Fig. 3

2

1

1

If the customer's reported fault persists, contact Te.Se.O. Do not carry out any interventions and/or replacements.


Date of last update

Closing date Notes


27/06/08



17

Sheet 21e – Alfa 159 VERSIONS All models CUSTOMER'S REPORTED FAULT Vibration/noise from gearshifting lever, in particular in third gear RESULT OF WORKSHOP ANALYSIS Customer's reported fault confirmed OPERATION Once the customer's reported fault has been confirmed, perform the below mentioned inspections/controls:

Step Control Ok Ko

1 Check the correct routing of Bowden cables inside the central tunnel and the engine compartment

Move on to step 2

Restore the routing of Bowden cables and retest the car to be sure that the fault is no longer present

2 Check the correct fastening of Bowden cables inside the central tunnel and the engine compartment

Move on to step 3

Restore the fastening of Bowden cables and retest the car to be sure that the fault is no longer present

3 Check the correct adjustment of Bowden cables

Move on to step 4

Restore the adjustment of Bowden cables and retest the car to be sure that the fault is no longer present

4 Car production date after 10/2007. Move on to step 5

Replace the Bowden cables with those available at Spare Parts and retest the car to make sure that the fault is no longer present

5 If the car production date is after 10/2007. If the fault persists after all the above described actions. Send a report to Te.Se.O.


Date of last update

Closing date Notes

21e Page 1/1 159 Gearshifting lever vibration

17/07/08



18

Sheet 22 – Alfa MiTo VERSIONS All models CUSTOMER'S REPORTED FAULT Seat belt locking RESULT OF WORKSHOP ANALYSIS Customer's reported fault confirmed OPERATION • Check the locking of the seat belt by trying to remove the belt • If the belt is locked, proceed as follows:

- Grasp the belt in the area indicated in the picture


Date of last update

Closing date Notes

22 Page 1/3 MiTo Seat belt locking 05/09/08



19

- Forcefully pull the belt section outside of the finishing (snapback trap and end stirrup on the seat) as shown in the picture

- Release the belt so that it goes back a few millimetres into the rewinder


Date of last update

Closing date Notes




20

If the belt is still locked, disassemble the rewinder section, loosen the rewinder fastener and remove the belt. If the customer's reported fault persists even after these operations, contact Te.Se.O. Do not carry out any interventions and/or replacements.


Date of last update

Closing date Notes




21

Sheet 23 – MiTo VERSIONS MiTo (1.4 Tjet) already under SN 33.01.09 for brake screeching CUSTOMER'S REPORTED FAULT Noise/screeching when braking, even after the implementation of SN 33.01.09 RESULT OF WORKSHOP ANALYSIS Noise/screeching when braking the car, tested on road, even after implementation of SN 33.01.09 FRONT BRAKE PADS. OPERATION In case of recurrent noise/screeching when braking notwithstanding the implementation of SN 33.01.09, follow the checklist below to make sure that: - The SN has been correctly implemented; - The components have been fitted according to the SN cycle instructions;

CHECKLIST TO BE COMPLETED AND SENT TO Te.Se.O. Control outcome

Were 1 sheet kit + 1 brake pad kit per side installed? (2 brake pad kits + 2 sheet kits are necessary per cars) YES NO

Is the part no. of the sheet kit installed on the car 77365201, as indicated in the SN (2 kits per car)? If not, indicate the installed part number: ---------------------------

YES NO

Is the part no. of the brake pad kit installed on the car 77364716, as indicated in the SN (2 kits per car)? If not, indicate the installed part number: ---------------------------

YES NO

Were the sound-proof sheets correctly positioned? (See references in Fig. 1) YES NO

Were the brake pads installed correctly (as indicated in SN 33.01.09 and/or the service manual)? YES NO


Date of last update

Closing date Notes

23 Page 1/3 MiTo Brake screeching 24/04/09



22

THE SHEETS ARE POSITIONED CORRECTLY WHEN: - the two tabs a (a - Fig. 1) rest firmly on the upper edge of the back of the brake pads (c); - the engraved arrows (b) are oriented in the direction of rotation of the disc and coincide with those of the brake pads (c); - the left internal pad (no. 132010) does not require an arrow since the wear indicator already indicates the position of the brake pad inside of the left caliper. Fig. 1

Key

A. Running direction B. Front axle (front brake discs) a. support tabs for the sheet on the pad b.-c. disc direction of rotation 132010 Left internal pad for left disc with wear indicator 132011 Left external and right internal pad 132012 Right external pad


Date of last update

Closing date Notes




23

NOTE: In a batch of pads produced in 2008, the arrow (c - Fig. 1) indicating the correct positioning of the pads was not printed. In this case, in order to correctly position the pads, it is necessary to refer to the numbers printed on the brake pads that can be used as a reference rather than the arrows (see Fig. 1). If the fault persists (brake screeching) after performing the controls reported in this newsletter, contact Te.Se.O. and send the above mentioned checklist.


Date of last update

Closing date Notes




24

Sheet 24ts – Various models

VERSIONS All models

CUSTOMER'S REPORTED FAULT Specific fault to Media Player (MP3) – USB – iPod Specific faults to handsfree phone

RESULT OF WORKSHOP ANALYSIS Preliminary control (for all types of faults)

OPERATION Read the following guided diagnosis to solve Blue&Me problems; if the problem persists, proceed with the TUTORSHIP request (in the Markets where it is active) or draft a TK for Te.Se.O. attaching the following checklist


Date of last update

Closing date

Convergence device Part no.: SW version: Device used: (note down the mobile phone and USB device used by the customer) Mobiles used USB devices used

Manufacturer: Files contained (Ex. MP3; WMA)

Mobile model: SW version: Manufacturer:

USB model:

Operator brand: Note: Has the customer activated the services? Yes No Which ones? Blue&Me help desk Ticket No. Customer's reported fault:

Notes

24ts Page 1/4

Various models Blue&Me - Blue&Me nav 24/04/09 18/12/2009 Table

modified



25

PRELIMINARY CONTROL (for all types of faults)

OK Check the SW

version and move on to step 3 1 Connect the Examiner and try to enter the

diagnosis Diagnosis trial

KO Move on to step 2

OK Continue with the Tutorship request

on ESIGI 2 Check the correct operation of the electrical system (power supply and CAN network)

Check power supply and CAN

network KO Repair the detected failure

YES Implement SN

3 With the Examiner, enter the diagnosis with the Convergence control unit and print the SW version and possible errors found. Check if there are any SN for the read SW version

Availability of SN for SW

update NO Continue with the Tutorship request

on ESIGI

YES Continue with the checklist 4 Check that the LED of the USB key is lit up USB LED

NO Check USB port wiring

SPECIFIC FAULT TO MEDIA PLAYER (MP3) – USB – iPod If the media player does not correctly play the file when the USB key is inserted, perform the following controls:

OK

5

Check that the Convergence control unit is not a C1V1 because this model does not allow for Media player function (the USB port on the control unit only serves to update the language and the software).

Convergence control unit KO

Move on to step 6

OK Move on to step 7

6 Check that the "AUTOMATIC PLAY" function is active. To know how to activate the different functions, read the Owner Handbook.

"Automatic play" function KO

Activate the “Automatic play"

mode OK Move on to step 8

7 Check the wiring/connectors Wiring/connectorsKO Restore the

connections OK Move on to step 9

8 Check that the format of the files used is that called for by the Owner Handbook. File format

KO Use only the files

called for

OK 9 Check the Media player operation using a USB

key other than the customer's USB key KO

Continue with the Tutorship request

on ESIGI


Date of last update

Closing date Notes

24ts Page 2/4


modified



26

iPOD


10 Check that the iPod model used is configured to be used as a mass memory device, not all models have this characteristic

iPod model KO

Read the manufacturer's

manual OK Move on to step 12

11 Check that the i-Pod used is not formatted for Apple Formatting

KO Format it for Windows as

described in the OH

OK Continue with the

Tutorship request on ESIGI 12

Check that the file formats downloaded on the iPod are those that can be read by the Blue&Me, as indicated in the Owner Handbook

File format

KO Use compatible formats

SPECIFIC FAULTS TO HANDSFREE PHONE


13

Check that the SW model and version of the mobile phone are compatible with the system, as reported on the Brand's commercial site

(www.fiat.com – www.alfa.com – www.lancia.com )

SW model/version of

mobile KO Use a model and/or

compatible SW

OK Move on to step 15 14

HANDSFREE VOLUME LOW INSIDE OF THE PASSENGER COMPARTMENT: check RADIO menu settings (External Audio)

RADIO menu settings KO Adjust the volume

OK Send report to Tutorship 15

THE LISTENER HEARS DISTORTED TELEPHONE CALL VOLUME: check the wiring and connectors to the microphone

Microphone wiring/connectors KO Restore the

wiring/connectors


Date of last update

Closing date Notes

24ts Page 3/4


modified

http://www.fiat.com/

http://www.alfa.com/

http://www.lancia.com/



27

GPS – CAR LOCATOR


16

With the car outdoor, enter the diagnosis mode with Blue&Me nav (Convergence) using the Examiner and check that there are no errors concerning:

- GPS ANTENNA - GPS MODULE

Errors detected with Examiner KO

Send report to Tutorship

< 3 Check the

conformity of the cable

17 Check the satellite number received by the systemSatellites

received by the system > 3

Send report to Tutorship

ROUTE CALCULATION (Blue&Me NAV)

OK Move on to step 19 18 Check the USB key (the Mapsregion directory with

contents having a .psf extension must be present) KO Refer to the OH

< 3 Check the

conformity of the cable 19 Check the satellite number received by the system

> 3 Send report to

Tutorship

If the problem persists, describe the fault: ............................................................................................................................................... ...............................................................................................................................................


Date of last update

Closing date Notes

24ts Page 4/4


modified



28

Sheet 25 - Alfa - 159 VERSIONS All models CUSTOMER'S REPORTED FAULT Steering housing noise and/or power steering noise while driving, on rough grounds and/or while parking. RESULT OF WORKSHOP ANALYSIS Customer's reported fault confirmed OPERATION Once the customer's reported fault has been confirmed, carry out a detailed diagnosis of the problem, following the instructions in the diagnosis sheets H005, H006, H010, H011, H020, H021. At the end of the diagnosis, do not carry out any replacement, rather fill in the claim sheet here below and contact Te.Se.O.


Date of last update

Closing date Notes

25 Page 1/2 159 Power steering noise 25/09/09



29

FAULT CLAIM SHEET WORKSHOP: _________________________ Street ____________________ Town ____________ Reference contact _____________________________________ Phone _______________________ Car chassis _________________________________________________________________________ Engine _____________________________________________________________________________ Car production date ___________________________________________________________________ Mileage _____________________________________________________________________________ Tyres ______________________________________________________________________________ Customer's reported fault _______________________________________________________________ ___________________________________________________________________________________

Workshop testing result ________________________________________________________________ _____________________________________________________________________________________________

OTHER NOISES

Rumbling while rotating Speed [rpm] ......................... NOTES:

Rumbling in neutral Speed [rpm] .........................

Rumbling in end of travel position

Whistling while rotating Speed [rpm] .........................

Whistling in neutral position Speed [rpm] .........................

Whistling in end of travel position

Knocking in reverse

Knocking in end of travel position

Steering wheel vibrations Speed [rpm] .........................

POWER ASSISTED STEERING Resistance NOTES: High load

Sudden hardness

Visual control of components during repair ...................................................................................................... ...........................................................................................................................................................................

...........................................................................................................................................................................

Other remarks ................................................................................................................................................... ...........................................................................................................................................................................

...........................................................................................................................................................................

...........................................................................................................................................................................

POWER STEERING RESERVOIR CONTROL Oil level ............................................................................................................................................................. Emulsion ........................................................................................................................................................... Oil leaks from the system ................................................................................................................................. (1) no power assisted steering in fast turns



30

Sheet 26 – Alfa MiTo VERSIONS All models produced from 2008 not subject to Tutorship CUSTOMER'S REPORTED FAULT Missed operation / irregular operation of the car electrical and electronic components (central locking, power windows, code, lighting, windscreen wiper, etc.) resulting from Body Computer failures. RESULT OF WORKSHOP ANALYSIS Check that the failure is really due to the Body Computer rather than to loose connection or failures of the component claimed as faulty (e.g., if the failure is on power windows, before replacing the Body Computer, make sure that all the system connections are OK and there are no problems on the push-button panel, on the power window motor, on the operating mechanism, etc.). OPERATION If the claimed fault is confirmed, do not replace the Body Computer immediately, rather make the following checks. If the claimed fault is confirmed:

• Connect the Examiner, enter the diagnosis function and save a first diagnosis printout with the error reports;

• If possible, delete the errors found; • Disconnect the battery, connect and reconnect the Body Computer (according to

the procedure on the e-LEARN manual) and reconnect the battery, paying special attention to make tight connections;

• Test the car making sure everything works correctly and save a second diagnosis printout to detect possible errors.

After the intervention, make sure the failure does not occur again. If the failure persists, before replacing the Body Computer contact Te.Se.O. attaching Examiner printouts with the detected errors to the Ticket.


Date of last update

Closing date Notes

26 MiTo Missed operation/irregular operation of electrical components 09/12/09



31

Sheet 27 - Alfa – 159 – Brera/Spider VERSIONS 2.0 JTD CUSTOMER'S REPORTED FAULT Occasional white smoke coming from the front side of the engine compartment. RESULT OF WORKSHOP ANALYSIS The white smoke is visible by the customer as well, during the regeneration procedure. Removing the aluminium guard of the turbocharger and disassembling the V-Clamp, the turbocharger-DPF filter matching is not aligned. OPERATION Check the engine oil level: if it is above max. level, drain oil to restore the correct level. Remove the turbocharger guard and release the V-Clamp, start the engine and make a forced regeneration with the Examiner; if exhaust gas comes out, stop the engine and realign the turbocharger and the DPF, then reassemble the V-Clamp. Before reinstalling the aluminium guard, test the car again forcing a new regeneration; if the claimed fault disappears, reinstall the aluminium guard and recheck the oil level. If it is correct, hand over the car to the customer. If the problem persists, contact Te.Se.O. without replacing any component.


Date of last update

Closing date Notes

27 Various models

Occasional white smoke from the front area

18/12/09



32

Sheet 28 – Various models Start&Stop VERSIONS All models with Start&Stop system . IMPORTANT COMMUNICATION Due a wrong writing, the error diagnosis P0555 on the cars with Start&Stop system does not refer to an error on the brake pedal, rather to an error on the brake servo vacuum sensor. The description will be corrected with the next Examiner release. In case of error P0555

- By Examiner, print the errors in the Body Computer control unit.

After collecting the required information, contact Te.Se.O without carrying out further interventions and/or replacements; attach the diagnosis printouts to the TK.

Sheet Model Subject Release date Date of last update

Closing date Notes

28 Various models Examiner writing error 29/01/10



33

Sheet 29 – Various models

VERSIONS All models, LPG supply. NOTE: remember that when reference is made to Tutorship, the reports must be sent through the appropriate eSIGI channel, whereas in Areas where they are not present, draft a TK for the Te.Se.O. of your Market, according to the standard procedure.

CUSTOMER'S REPORTED FAULT Switching off when idling with LPG supply engaged.

RESULT OF WORKSHOP ANALYSIS When LPG supply is engaged, occasionally the engine switches off without storing any error in the control unit.

ACTION If the claimed fault persists, proceed as below indicated:

1. check the correct LPG injector sequence, as shown in FIG. 1

FIG. 1

Release

date Date of last

update Closing

date Sheet Model Subject Notes

29 Switching off when idling with LPG supply engaged.

Various models 24/02/10 page 1/2



34

2. Start engine parameter acquisition. 3. Reset the self-adaptive parameters (including Throttle Body and Toothed wheel).

If the fault persists, check tappet clearance; if it is wrong, restore the correct tappet clearance.

If, in spite of the above operations, the fault still persists, contact Te.Se.O. without carrying out further interventions and/or replacements; attach the diagnosis printouts to the TK. Te.Se.O. shall supply further information on how to handle the matter.


Date of last update

Closing date Notes

29 page 2/2

Various models

Switching off when idling with LPG supply engaged. 24/02/10



35

Sheet 31 – Various models with DPF

VERSIONS All models New CCM software with addition of Recovery.

CUSTOMER'S CLAIMED FAULT The engine does not perform/does not start.

RESULT OF WORKSHOP ANALYSIS Found errors P0521 P0524 in the CCM

ACTION After reprogramming the CCM with the latest DPF handling SW, two Recovery levels were added, to protect the engine from damage due to the lacked control of the engine warning light by the customer.

These two Recovery situations are handled by the CCM by setting two errors, when the oil degradation exceeds two thresholds:

P0521 for the "lightest" Recovery

P0524 for the "heaviest" Recovery

These errors can be removed only by changing engine oil.

Therefore, if errors P0521 or P0524 occur, engine oil must be changed.

Note: if the CCM is upgraded before the engine oil replacement, if the oil degradation has exceeded the relevant threshold, the relevant error is validated and the engine recovery is set.


Date of last update

Closing date Notes

31 Various models

The engine does not perform/does not start 23/04/10



36

Sheet 32 – Alfa Spider VERSIONS All models

CUSTOMER'S CLAIMED FAULT Any soft top system malfunctioning

RESULT OF WORKSHOP ANALYSIS Customer's reported fault confirmed

ACTION If the claimed fault is confirmed, implement Service News 70.01.10; if the customer's claimed fault persists, do not make and replacements and/or intervention and report the case to Te.Se.O.

Note. Te.Se.O. has a specialised technician for handling soft top cases and, for possible critical situations, it has been agreed to send specialised technicians to the workshop.


Date of last update

Closing date Notes

32 Various models Soft top malfunctioning 23/04/10



37

Sheet 33 – Alfa MiTo Seat Belt Reminder Buzzer and display for seat belt fastened VERSIONS All models CUSTOMER'S CLAIMED FAULT

1. Missed switching off of seat belt buzzer even though the driver's seat belt is correctly fastened.

2. Missed/wrong signalling of passenger's presence on front seat on the display over the inner

rear view mirror (picture below).

RESULT OF WORKSHOP ANALYSIS Check the customer's claimed fault ascertaining that one or both faults are really occurring. In the event of missed switching off of seat belt buzzer even though the driver's seat belt is correctly fastened (claim 1), check that the wiring of the seat branch under the driver's seat is not pinched in the seat height adjustment mechanism.

Release date

Date of last update

Closing date Sheet Model Subject Notes

33 Missed switching off of seat belt buzzer 21/05/10 18/06/10 MiTo Page 1/3



38

ACTION 1. Missed switching off of seat belt buzzer even though the driver's seat belt is correctly fastened. If the belt branch wiring under the driver's seat is damaged, replace it. Protect the new wiring with a corrugated sheath or similar, so that it does not interfere with the seat height adjustment system. Make sure that the fault has been solved; if the problem persists, contact Te.Se.O. 2. Missed/wrong signalling of passenger's presence on front seat on the display over the inner rear view mirror (Seat Belt Reminder).

According to the design of the passenger's presence detection and signalling system, the indication on the central display could be inconsistent vs. the current conditions of the passenger's seat (free or occupied). In particular, when the passengers' builds are too small or too large, the system could give wrong signalling messages or not be able of detecting the passenger's presence.

The missed recognition of occupied passenger's seat by the SBR display does not have any effect on the operation of the additional car restraint devices. The restraint systems (air bags, pre-tensioners) are directly operated by the seat branch, sending a priority signal vs. the passenger's detection sensor on the passenger's seat cushion. Therefore, all safety devices are working correctly. If an irregular SBR system operation is claimed, do not replace the sensor on the passenger's side seat (picture below), as the customer's claimed fault could be impossible to solve. Check if repositioning the sensor vs. the seat, the system capability of locating the passenger improves.


Date of last update

Closing date Notes

33 Page 2/3 MiTo Missed switching off of seat belt

buzzer 21/05/10 18/06/10



39

The SBR wrong signalling in the even of special passengers' sizes is not due to a fault of the sensor, rather to one of its peculiar features. For further details, contact Te.Se.O.

Release date

Date of last update


33 Missed switching off of seat belt buzzer 21/05/10 18/06/10 MiTo Page 3/3



40

Sheet 34 – Alfa MiTo

VERSIONS

All models

CUSTOMER'S CLAIMED FAULT

1. Failed centring of the steering wheel in the straight wheel position (misaligned steering spokes, as per picture below).

2. The vehicle tends to drift while running on a straight path.

RESULT OF WORKSHOP ANALYSIS

While driving, with steering wheel straight, check if the car shows a slight drift. If the fault occurs, firstly check the front and rear tyre pressure, making sure that these values are correct. Also check the tyre wear. If the wear of the four tyres is irregular, the drift could be caused by them.

Release

date Date of last

update Closing

date Sheet Model Subject Notes

34 Steering wheel centring 18/06/10 MiTo Page 1/3



41

ACTION

- Carry out a road test, to reproduce the condition of straight driving with misaligned steering wheel: On a straight road, without slopes that can be perceived with the naked eye, make a test at steady speed, without any pulling, release or braking movements. In the above test conditions, find out the steering wheel balance position that keeps a straight path and check if the spokes are centred or not. If, while turning the steering wheel a bit, the position of the correct straight path can be achieved, the problem concerns steering wheel alignment/toe in.

- End the road test and check the front toe in on bench: With straight steering wheel, check if the front toe in is beyond the allowed tolerance (see table below).

Technical data>3. Manufacturing data>3.3 44 suspensions and wheels>3.3.1 4450 hubs and wheels>3.3.1.1 front wheel geometry

Measurement Value Validity

Front geometry – protrusion height (mm) 664 +/- 5 (Standard 0)

1.4 16v 1.4 MultiAir 1.3 MultiJet 1.6 JTD 16v

Front geometry – protrusion height (mm) 660 +/- 5 (Standard A)

1.4 16v 1.4 MultiAir 1.3 MultiJet 1.6 JTD 16v

Front geometry – protrusion height (mm) 662 +/- 5 (Standard 0) 1.4 16V Tjet 1.4 MultiAir

Front geometry – protrusion height (mm) 655 +/- 5 (Standard A) 1.4 16V Tjet 1.4 MultiAir

Front wheel toe in (mm) - 1 - +/- 1 mm (Standard 0 and Standard A)

Front wheel camber (degrees) - 27’ +/- 20’ (Standard 0 and Standard A)

Front pillar caster (degrees) + 3° 29’ +/- 30’ (Standard 0 and Standard A)


Date of last update

Closing date Notes

34 Page 2/3 MiTo Steering wheel centring 18/06/10



42

- In case of positive result, adjust the front toe in restoring the preset values (above table).

- After adjusting the toe in, without moving the vehicle from the geometry adjustment bench, adjust the steering shaft sensor calibration for a correct centring of the steering wheel.

N.B. For the correct memorisation of the steering shaft calibration parameters, wait about 10 seconds after key-off (control unit power latch), before making a new key-on.

- Test the car to make sure that the fault has been solved.

If the fault persists, contact Te.Se.O.


Date of last update

Closing date Notes

34 Page 3/3 MiTo Steering wheel centring 18/06/10



43

Sheet 35 – Alfa MiTo

VERSIONS

All models with manual climate control system having 3 knobs.


Possible detachment of climate control system knobs during use (versions with manual climate control system), due to a fault in the supply process.


On the cars with manual climate control system (controls with 3 knobs: A, B, C in the figure below), entering the workshop for repairs or PDI operations, check that the climate control system knobs do not come out from their mounting. For the check, you need to fully rotate all three knobs to the right and to the left, then try to remove them from the mounting (without forcing). The knobs should not detach.

The figure shows the manual climate control system control panel. For the check, rotate all knobs to their end of travel and then try to release them.

Release date

Date of last update


35 Manual climate control system knobs 22/07/10 MiTo Page 1/2



44

ACTION

If, after the check, the knobs should detach (one or more than one), replace the faulty knobs and make sure that the problem does not reoccur.


Date of last update

Closing date Notes

35 page 2/2 MiTo Manual climate control system

knobs 22/07/10



45

Sheet 36 – Alfa Giulietta

VERSIONS

All models with dusk sensor option


The dusk sensor is not working.


The dust sensor does not work properly.

ACTION

Check by EXAMINER the SW release of the BCM control unit (Body Control Module): if it is after or equal to release F07/08, continue troubleshooting. If the SW is before release F07/08, perform a battery Disconnection/Reconnection. If the fault is not solved, continue troubleshooting.


Date of last update

Closing date Notes

36 Giulietta Failed operation of the dusk sensor 22/07/10



46

Sheet 37 – Alfa Giulietta

VERSIONS

All models


None. The fault can be checked only at the workshop, after replacing a component requiring a Proxi procedure.


Impossible to carry out PROXI alignment.

ACTION

Check by EXAMINER the SW release of the BCM control unit (Body Control Module): if it is after release F07/08, continue troubleshooting. If the SW is before or equal to release F07/08, perform a battery Disconnection/Reconnection. If the fault is not solved, continue troubleshooting.


Date of last update

Closing date Notes

37 Giulietta Missed PROXI alignment 22/07/10



47

Sheet 38 – Alfa MiTo Oil consumption – 1.4 petrol MultiAir 105 HP engine

VERSIONS

All models with 1.4 petrol MultiAir 105 HP engine (aspirated engine and NOT turbocharged one)


• Too high oil consumption (over 120 g/1,000 km), oil level visibly under the minimum mark every 10,000 km

• Irregular operation, with EOBD warning light switching on • Some light blue smokiness at the exhaust during starting


If the customer claims a too high engine oil consumption, or in case of different workshop operations on cars having 1.4 MultiAir 105 HP engine, keep under control the oil level to determine the consumption. Check the residual oil quantity in the sump, the frequency of topping up and the possible memorisation of errors in the CCM.

ACTION

If the analyses show: • reduced oil quantity in the sump (about 1.5 l compared with the min. level of 2.2 l). • CCM errors: P300÷304 (misfiring) and/or P069/P106/P111 (plausibility of sensor for

intake manifold temperature/pressure) • Presence of oil in intake and in the chamber on the head cover, under the PCV

valve. Restore the correct engine oil level, making sure that the max. allowed oil mark is not exceeded, using products complying with the specifications of the Owner Handbook (table below).


Date of last update

Closing date Notes

38 MiTo Excessive oil consumption 03/09/2010



48

FLUIDS AND LUBRICANTS

SPECIFICATIONS AND RECOMMENDED PRODUCTS

Use Fluid and lubricant features for a correct use of the car

Genuine fluids and lubricants

Lubricants for petrol engines

SAE 5W-40 ACEA C3 grade totally synthetic lubricant FIAT Classification 9.55535-S2

SELENIA K P.E. Contractual Technical Reference No. F603.C07

Remind the customer to make a regular check of engine oil level, as described on the Owner Handbook.

Do not modify engine mechanical components nor engine management/control software in any way. For critical situations, contact Te.Se.O. or, where available, the Tutorship.

NOTE: The tampering with the engine and/or the use of lubricants with specifications inferior to ACEA C3 and SAE grade other than 5W-40 could cause damage to the engine not covered by the warranty.


Date of last update

Closing date Notes

38 MiTo Excessive oil consumption 03/09/2010



49

Sheet 39 – Various models (159 – Brera – Giulietta)

VERSIONS

1.8 TBI

NOTE: remember that when reference is made to Tutorship, the reports must be sent through the appropriate eSIGI channel, whereas in Areas where they are not present, draft a TK for the Te.Se.O. of your Market, according to the standard procedure.


EOBD warning light switching on/engine irregular operation.


The Engine Management Control unit memorised one or more of the following error codes, concerning the oxygen sensor operation: P0130, P1135, P0136, P0134.

ACTION

By Examiner, print the errors in the engine management control unit. After collecting the required information, contact Te.Se.O. without carrying out further interventions and/or replacements, attaching the diagnosis printouts to the Tk.


Date of last update

Closing date Notes

39 Various models EOBD warning light switching on 27/09/10

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