Engine warning light & black smoke while changing gear - Alfa Romeo Forum
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(Post Link) post #1 of 25 Old 05-09-16 Thread Starter
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Engine warning light & black smoke while changing gear

Hi,
My engine warning light has been on for almost a year, but it's intermittently on. I also get right side light failure and left side light failure someone both one after the other and sometimes just the right light.

But the lights are fine and I have serviced the car and they have changed the bulbs.

About 3-4 months ago when changing gear I noticed that the exhaust throws out black smoke, sometimes white. But recently it's sending it out when accelerating.

My car has 104k miles on the clock now. Could this be the cause?
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Have you checked with diagnostics to find out why the engine management light is on?
If you haven't, do it. No point guessing.

Excess smoke is never a good sign. Has it had a remap? Is it using oil? What oil are you using?

104000miles is nothing and on its own is not the reason for your problems.
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(Post Link) post #3 of 25 Old 05-09-16 Thread Starter
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I have had my friend use his diagnostic computer and it's just coming up with loads of errors from lights to airbags, we have tried to pin it down but cannot find the exact thing. It does not have a re-map. The engine oil put into it in it's last service is 5w-40. It was doing this before the service.
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I'd suggest putting the battery up for a proper load test. A weak or failed cell can give you grief with phantom faults, this is not "an Alfa thing" but a common predicament with modern electronics in cars.
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I'd suggest putting the battery up for a proper load test. A weak or failed cell can give you grief with phantom faults, this is not "an Alfa thing" but a common predicament with modern electronics in cars.
Weak battery's don't cause smoke to come out of the exhaust, and if it was a dodgy battery causing the error lights then it's been hanging on for almost a year....

Airbag errors aren't uncommon at all, often can be fixed by addressing a dodgy electrical connection somewhere.

Black smoke whilst accelerating is often a symptom of over-fueling, of which there are a number of possible causes... Do you get any whooshing/whistling noises at the same time? Does the car feel down on power at all?
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Ahh,
Ok so the battery was replaced by the AA because the original battery died on me around two years ago.

Overfueling by me? or too much fuel going in?
I do get a wooshing kind of noise like if the car is doing an impression of K.I.T.T from Knight Rider.
The car does feel down on power, and sometimes when I accelerate I do not move too quick until the rev counter does to 2-3 revs from a 1st gear start.
When I am in 4th and I accelerate to 40 it takes a second or two longer and the black smoke comes out.
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I've never changed any fuses since having the car.
I haven't chaned the timing belt or water pump. My friend said I should change that as a matter of importance.
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Overfueling by me? or too much fuel going in?
I do get a wooshing kind of noise like if the car is doing an impression of K.I.T.T from Knight Rider.
The car does feel down on power, and sometimes when I accelerate I do not move too quick until the rev counter does to 2-3 revs from a 1st gear start.
When I am in 4th and I accelerate to 40 it takes a second or two longer and the black smoke comes out.
Too much fuel (or too little air) going into the cylinder, causing incomplete combustion and a load of smoke as a by-product.

Whooshing noises, smoke out the back, down on power, laggy response at low revs.. All indicate boost leak and/or VNT issues... Easy fix in either case!

Take a look under the bonnet, the big hose on the right that goes over the battery - any holes or splits in this?

There's another big hose down low behind the bumper - this one fails more commonly but is harder to see without lifting the car on a jack or with wheel ramps.

VNT issues are often due to split/leaks in the vacuum hoses around the VNT actuator and solenoid - again a nice simple fix if you find an issue here.

As far as timing belt and water-pump goes - they should both be replaced (along with a belt tensioner, and idler pulley) every 60k miles OR 5 years - whichever is soonest.

Do you know if/when your car has had one in the past? If you've got no record of it every being done, then yes it needs doing ASAFP.
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Where is the VNT located? I dont think it's ever been done.
I've had the car from 30k
Perhaps it had been done before I bought it, but I doubt it.
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On the 1.9JTD there was a stud on the gearbox that would gradually punch a hole in the intake hose that runs past it as it expands under boost. With it turned off, you may not see the hole.
That loss of air then equals an excess of fuel which results in the smokescreen.
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Just sounds like the usual, a faulty/clogged EGR valve, lack of power at low revs and black smoke. Much easier if you simply read the codes as has already been suggested. Just look at the engine codes and forget the rest which have nothing to do with the Engine Fault light being on. Wasting your time trying to guess when the car is already helping you pinpoint the cause reasonably accurately.
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Ahh,
Ok so the battery was replaced by the AA because the original battery died on me around two years ago.

Overfueling by me? or too much fuel going in?
I do get a wooshing kind of noise like if the car is doing an impression of K.I.T.T from Knight Rider.
The car does feel down on power, and sometimes when I accelerate I do not move too quick until the rev counter does to 2-3 revs from a 1st gear start.
When I am in 4th and I accelerate to 40 it takes a second or two longer and the black smoke comes out.
You could save some quids with a little bit of reading on here and some slightly oily hands. A garage could easily stick you for a couple of hours labour and make no progress on this. Keep us all informed and I'm fairly confident you have some classic jtdm faults that are easily rectified.

As stated by others the whoosh can come from a boost leak. The lower hose is the weaker of the 2. You should be was to locate if a friend revs while you listen under the front of the car.

Vnt hoses, maf, map and egr are all posinke culprits easily diagnosed with some basic diy.

Probably a good idea to get on top of the other issues and service items before your 147 spits out its dummy.

Don't buy cheap bulbs as the canbus doesn't like them. Get osram not Halfords and this could stop spurious dash lights. I've had working bulbs give messages. Replaced them with quality branded items and all was good.

Last edited by dgmayhead; 05-09-16 at 18:44.
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(Post Link) post #13 of 25 Old 05-09-16 Thread Starter
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Just sounds like the usual, a faulty/clogged EGR valve, lack of power at low revs and black smoke. Much easier if you simply read the codes as has already been suggested. Just look at the engine codes and forget the rest which have nothing to do with the Engine Fault light being on. Wasting your time trying to guess when the car is already helping you pinpoint the cause reasonably accurately.
Hi Alexie,
It's not the ERG value as my friend opened up the pipe to it and looked inside it was clean. There was only a very slight amount which we cleaned away with his degreaser spray.
He did say to get a plate to not have the fumes go back into the engine, but he did also say that wouldn't solve the problem just something to do.
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Hi Alexie,
It's not the ERG value as my friend opened up the pipe to it and looked inside it was clean. There was only a very slight amount which we cleaned away with his degreaser spray.
He did say to get a plate to not have the fumes go back into the engine, but he did also say that wouldn't solve the problem just something to do.
I'd definitely recommend blanking the egr.

There's a big hose on the right of the engine bay. When you rev the engine this goes hard. It's called the top boost hose and if it has a leak you will have too much fuel and not enough air. Check it by looking and listening. Another hose of similar proportions is under the front of the car. This is the lower boost hose. Check it doesn't leak. As David says it rubs somewhere and eventually fails.

The vnt hoses are tiny rubber hoses that have a vacuum in them that controls the turbo. They get splits and hence the turbo doesn't boost enough. If can't find any blue, red or shiny black silicon small hoses your car probably has the original rubber hoses. They will certainly be leaking. Fortunnately they cost very little and can be pulled of and pushe don by hand..
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Read the fault codes on the engine ECU again and post them up, otherwise we're all just guessing. It might be worth taking it to an Alfa specialist and getting it health-checked.
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Read the fault codes on the engine ECU again and post them up, otherwise we're all just guessing. It might be worth taking it to an Alfa specialist and getting it health-checked.
Very true but a big whooshing hole in the turbo hoses is pretty easy to look for while you're waiting for amazon prime to deliver your elm cable.
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Hi Alexie,
It's not the ERG value as my friend opened up the pipe to it and looked inside it was clean. There was only a very slight amount which we cleaned away with his degreaser spray.
He did say to get a plate to not have the fumes go back into the engine, but he did also say that wouldn't solve the problem just something to do.
The problem isn't to do with it being clogged more often than not, it's to do with it not closing properly. This shows up as a lack of power at low revs, suddenly bursting into life at 2,500 rpm and above. Also tends to smoke a lot. Could be the other things mentioned, boost leaks etc, but an EGR that is stuck partially open, because of sooty deposits jamming the valve head, seems to be very common and is very easy to check (blow through it off the car).
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I'm getting similar problems with my 1.9 GT. This is the fault code. Don't know where to start.

http://uploads.tapatalk-cdn.com/2016...d32ae13c99.jpg


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I'm getting similar problems with my 1.9 GT. This is the fault code. Don't know where to start.

http://uploads.tapatalk-cdn.com/2016...d32ae13c99.jpg


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Looks like you've connected to the body computer there - you need to connect to the engine ECU (sometimes called diesel injection) and see what codes are there.
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Engine warning light & black smoke while changing gear

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Looks like you've connected to the body computer there - you need to connect to the engine ECU (sometimes called diesel injection) and see what codes are there.


Ok. Sorry for being a little daft, but where exactly is the engine ECU located? The computer was plugged in, below the steering rack. We unscrewed the cover off, and found the plug where it was connected.




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Ok. Sorry for being a little daft, but where exactly is the engine ECU located? The computer was plugged in, below the steering rack. We unscrewed the cover off, and found the plug where it was connected.




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Its the same connection point, you can connect to any of the ECUs on the car through that plug. You just have to select the correct ECU on your diag equipment. You should see a list, it will normally have Airbag, ABS, Body computer, CAN, Diesel injection, Doors locking, Network alignment etc etc. Select the one called diesel injection, fuel injection, engine, something like that and then see what the codes are.
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I managed to find an Alfa Specialist, called Duncan Slade. The car is booked in for a full diagnostic check on Tuesday. Will see what the problem is.

Thanks for the input


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(Post Link) post #23 of 25 Old 12-09-16 Thread Starter
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Red Face Fixed the black smoke...

So I had a look under the bonnet on Sunday and found that the fluid containers were dirty again (my friend degreased them previously).
I then felt the back of the pipe and felt a 1 and a half inch cut.

So as you can see in the picture I have taped it up. No smoke at all now!

I drove to Manchester and as I got into the city centre the there was a strange noise like someone screaming coming from the front of the car.

Did I do wrong in taping it up?
While I was driving up I could still hear intermittently the whirring noise from before.

Is there another underlying problem?

Thanks for any help/advice
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So I had a look under the bonnet on Sunday and found that the fluid containers were dirty again (my friend degreased them previously).
I then felt the back of the pipe and felt a 1 and a half inch cut.

So as you can see in the picture I have taped it up. No smoke at all now!

I drove to Manchester and as I got into the city centre the there was a strange noise like someone screaming coming from the front of the car.

Did I do wrong in taping it up?
While I was driving up I could still hear intermittently the whirring noise from before.

Is there another underlying problem?

Thanks for any help/advice
It's just the noise of your repair not holding - air is getting through the tape. You need a new top hose.
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(Post Link) post #25 of 25 Old 12-10-16 Thread Starter
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Hi all,
So an update, I bought a pipe for £29. My friend and I fitted it in and it works just fine.

If my friend had not cleaned off the grease from the break fluid bottle and power steering bottle then I would not know the fuel was leaking from the back of the intake pipe.

Here is a video of what I did before the replacement pipe. It works but not for long:

I have noticed though that I can still get black smoke if I am in a low gear and I put my foot down, is this normal?

Thanks for all of your help and support.
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