I'm a transient owner of a 156 sw JT16V mjet (all-facelift).
She's got the looks, 120K KM, 17"alloys, nero metalico, blackish-bluish alfatex trim.
Recently got the EGR prank, and found out that I'm one of the unluckies non-wired for cruise-control.
About the EGR, 1.9JTD 16v mjet :
take engine cover, the three 10mm bolts (left-back is recessed)
look back, right, near inlet pipe. See a cube-sized alloy attached perpendicularly to the inlet? it has a black cilinder body attached to it (the solenoid)... that's your EGR.
I recomend taking the complete EGR out, them diassemble it... I first tried to go to the solenoid only, but there's very little tool-room to take out the bottom allens. Glad I took the body out, because it was reeeeeeallly stuck, and on the solenoid rod, nothing was wrong.
So, take your 8mm, 10mm and 12mm and unsrew the hole thing (8mm for a pipe stand on studs, 10mm for the egr body to inlet, 12mm for EGR-body to exaust-pipe under it. As you're about to finish the 12mm EGR body-pipe, recover the sealing (metalic, no high-pressures here so don't worry)... you'll need it.
Disconnect the electrical plug from the solenoid: there's a yellow strip that you need to move (screw driver) towards the cable. Only after that strip is some 4mm out are you able to pull the plug. The plug has rubber seals (don't worry, they don't get free), so be persistent.
Now you have the complete EGR on your hand. Check the inside:
There should be soot in it... but if you see small rocks of carbon in between the valve dish/seals, it's most likely about to be stuck.
To make sure it isn't stuck, remove the 4 allens that keep the solenoid in place. you'll see a dish capturing a spring where the solenoid pushes. Can you press the dish freely some 10mm? completely free? what about the solenoid rod?
If not, don't be very gentle, but restrain your brutality: on the EGR body, poke-out the carbon rock inside the passings. Go thouroughly into one end (exaust in), then the other (inlet in).
If the valve vain is still stuck, get your pressure-pliars and rotate it, from the solenoid end... it can be really stuck, but eventually you'll get it to rotate... as it rotates, you'll notice that finally the dish-seals on the body are coming backwards, to shut the valve opening.
Clean it, oil it, clean it again... the vain when freed takes less than 100g of force to fully move. Make sure the solenoid vain is also 100% freed.
Note to ALFA: WHAT A STUPID DESIGN!!! exaust soot passing through 20mm diameter cold-air dishes? a non-lubicated vain in contact with soot? someone should be fired over there.
Reassemble (don't forget the body-exaust pipe metal seal), reconnect electricals, go for a spin.
BUY A DECENT DIESEL TREATMENT PRODUCT, HARD DRIVE IT FOR AT LEAST 200KM (AUTOROUTE AT 200KM/h IS NOT HARD FOR THE EXAUST, GO MOUNTAIN CLIMBING!).
Also, bear in mind that another common failure on JTDs is contributing the EGR-seisure: thermostat stuck open, causing engine temps way below optimal. My case, between 50ºC and 70ºC... not good for soot build ups.
See you guys!