22 · Diagnostics

Excessive exhaust fumes

Make: Alfa Romeo
Model: GT Factory Service Manual
Year: 2003–2010
Section: Emissions › Excessive exhaust fumes

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Fault diagnosisExcessive exhaust fumes

EXCESSIVE EXHAUST FUMES

1.9 JTD 16V

Exhaust fume levelsl highs, with dense smoke and presence of particulate.

0	PRELIMINARY CHECKS	All OK	Problems met	Operation
		Results of the tests
	Preliminarily check: The engine oil level The condition of the air filter	Continue to Step 1	Oil level too high	Top up the engine oil level Op. Op. 0010T11 ENGINE OIL CHECK LEVEL AND TOP UP
		Continue to Step 1	Filter element dirty or damaged	Replace the filter element Op. Op. 1048A14 AIR CLEANER FILTERING ELEMENT - REPLACE.
1	CHECK WITH DIAGNOSTIC EQUIPMENT	All OK	Problems met	Operation
	Connect the Examiner diagnostic equipment to the diagnostic connector and check the engine conntrol node: For faults in error mode; In the parameters ambient, the plausibility of all the parameters	Continue to Step 2	An error is detected in the control unit	Continue following the instructions for the diagnostic equipment
		Continue to Step 2	unreliable parameters	Continue following the instructions for the diagnostic equipment
2	CHECKING BLOW-BY CIRCUIT	All OK	Problems met	Operation
	Check the condition of the blow-by gas intake circuit, in particular, check that there are no obstructions in the separator or the pipes	Continue to Step 3	Fault in the pipe from the intake to the separator	Restore the correct operation of the circuit: if necessary, replace the pipes
		Continue to Step 3	Fault in the separator	Restore the correct operation of the circuit: if necessary, replace the separator
3	AIR CIRCUIT CHECK	All OK	Problems met	Operation
	Check the condition and seal of the air supply circuit	Continue to Step 4	Circuit component damaged	Replace the damaged component
4	EGR actuator check	All OK	Problems met	Operation
	Carry out active diagnosis of EGR control solenoid	Continue to Step 7	Actuator not working	Continue to Step 5
5	EGR ELECTRICAL CIRCUIT CHECK	All OK	Problems met	Operation
	Check continuity/insulation of connections between engine control unit and EGR solenoid See See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT	Continue to Step 6	Electrical connection fault	Restore the connections See See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT
6	EGR ASSEMBLY OPERATION CHECK	All OK	Problems met	Operation
	Detach actuator from vehicle and dismantle the valve unit to check correct operation.	Continue to Step 9	Valve blocked open	Eliminate the cause of the blockage and replace the actuator if necessary Op. Op. 1080C24 E.G.R. SYSTEM SOLENOID - R + R
		Continue to Step 9	Valve free, solenoid defective	Replace actuator Op. Op. 1080C24 E.G.R. SYSTEM SOLENOID - R + R
7	CHECK ON CYLINDER COMPRESSION	All OK	Problems met	Operation
	Carry out the cylinder compression test Op. Op. 0510A10 CYLINDER COMPRESSION - CHECK FOR LOOSE SPARK PLUGS OR INJECTORS	Continue to Step 9	Cylinder compression insufficient	Continue to Step 8
8	CHECK ON CAUSE OF INSUFFICIENT COMPRESSION	All OK	Problems met	Operation
	- Carry out R.R. on head [PR_1016C10] to check the valve seal Check the condition of the cylinders/piston rings	Continue to Step 9	Insufficient valve seal	Overhaul the cylinder head Op. Op. 1016E10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL
		Continue to Step 9	Wear on cylinders/piston rings outside tolerance	Restore the correct clearances
9	CHECK ON CORRECT OPERATION	All OK	Problems met	Operation
	Check that the fault is no longer present	End of diagnosis

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Parts & tools for this job For 2003 Alfa Romeo GT

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