Alfa Giulia Won't Start, DEF Fluid Warning Points to Fix

Had a similar situation with my 2017 Alfa Giulia 2.2 JTDm. The DEF fluid system fault prevented engine starts after ignoring service warnings. The issue was more complex than just refilling the tank. The SCR catalyst system showed blocked DEF lines between the tank and dosing unit. The dried DEF fluid had crystallized in the lines, requiring a complete system cleaning. The emission standards compliance system is designed to prevent engine operation when DEF-related faults occur. The repair involved: Cleaning crystallized DEF from lines, Replacing the dosing module, Resetting emission control unit, Refilling with fresh DEF fluid, System calibration This was a serious repair requiring specialized diagnostic equipment. The fuel efficiency and overall engine performance improved noticeably after fixing the system properly. A simple DEF refill would not have solved the underlying issue. Recommend having your vehicle diagnosed at a shop with experience in diesel exhaust systems. The fault codes will indicate if you have similar crystallization issues or just need a fluid top-up.

Thanks for the detailed response about your Giulia repair. My Giulia is showing similar symptoms. Would you mind sharing what the total repair cost was? The problem seems similar with the tank capacity warning and emissions control system throwing faults. Also curious if youve had any other DEF system issues since getting it fixed?

Got my Giulia back from the shop yesterday. The AdBlue system is working perfectly now. The issue was exactly what I suspected, the connection between the tank and dosing unit was defective, causing the emissions control system to shut down. The total repair came to 250 Euro, which included fixing the output line and a fresh AdBlue fill. Much more reasonable than I initially feared. The fuel efficiency has actually improved since the repair, suggesting the system wasnt working properly for a while. No other DEF-related problems since the fix. The service light cleared immediately and the diesel exhaust system is functioning as intended. Would recommend getting yours checked soon, these issues tend to get worse if left unaddressed. The tank capacity sensor is now reading correctly too, which helps monitor AdBlue levels and prevent future problems. Its worth fixing properly to avoid any long-term damage to the emissions system.

The repair went better than expected. Took my Giulia to a specialist diesel shop that fixed similar issues before. The injection system was displaying multiple faults, but the mechanic found the root cause quickly, crystallized DEF fluid had damaged the dosing unit. Total cost was 480 Euro including: New DEF pump, System flush, Fresh fluid, Labor The dashboard alert cleared right after the repair. Engine starts perfectly now and the service light stays off. No more warning messages about the emission standards. They showed me the damaged parts and explained everything clearly, much better experience than my previous mechanic. Fuel consumption improved slightly too. Guess the DEF system wasn't working properly for a while. Will definitely keep a closer eye on the fluid levels from now on to avoid another system failure. Good investment considering the potential damage to the exhaust system if left unfixed. The shop also registered my maintenance in their system for warranty purposes.