Looking for fuel
Join Date: May 2007
Location: United Kingdom
I've had mine repaired with Heath Road Garage recently. Really good bunch of guys. The owner, Alfie, comes on here and owns an Alfa 159 2.4 Ti auto. He's had similar problems with his and did all kinds of research and in the end wound up just getting his hands dirty and working out the problem himself.
He's had a go on mine as the symptoms were the same. I think (hope) that mine is now just short of a new EGR valve to sort it completely. Your issues sound the same as mine, although I'm not doing journeys as short as you. I am about 10 miles each way to work on the M6, so the gauge gets up to full temp about half way along my motorway run. Hopefully this is ok?
I ended up having the inlet manifold removed, and cleaned in an acid bath, I think the throttle bodies were cleaned aswell. The EGR was removed and cleaned and the new improved restricted flow gasket was fitted.
This immediately reduced the amount of cranks required to start the car, the rough idling on start up was greatly reduced and the rough idle generally on tick over has gone.
The problem I am experiencing now has to be a sticking EGR, which can cause rough starting too. Which is starting to creep back in.
I intend to do a thread on this fix, but I've been so busy recently with other things that I haven't got round to it. The state of the inlet manifold due to the EGR valve was nothing short of shocking! I would say the airflow through the manifold was restricted by heavy coking to about 1/3 of what it should have been!!! (64k miles).
The sooner I get that retched EGR valve switched off with the DPF work and the remap the better. But I have to wait until next January for insurance reasons as my current insurer wont touch modded cars. Unless I just have the DPF hollowed out, and keep it to myself?!....