Early TS 16v - PCV valve and smoke after engine brake - Alfa Romeo Forum
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(Post Link) post #1 of 17 Old 20-07-14 Thread Starter
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Early TS 16v - PCV valve and smoke after engine brake

Hi!

I have a problem: after engine brake with high revs (over 4000 RPM), if I give gas, then thick blue smoke comes from the exhaust. In any other case (after low RPM engine brake, normal or hard acceleration, cold start, etc) there isn't any smoke.

The car is a 1996 GTV 2.0 TS.

Because of this, I thought, it would be a good idea to change the PCV valve (71713715), but my engine has an aluminium intake manifold (not plastic), and the breather hose goes in the throttle body.
Here is a metal connection piece, is this the PCV valve?
If so, what is the part number of this one?

I had to change the breather hose because a fire, caused by I broken spark plug.

I think the oil consumption (Selenia 20k) isn't too high (~1-2 dl / 500 km), but I need to check this later.

By the way can this symptom caused by overfilling the engine oil?

I will also change the intake gasket, and seal the variator solenoid.

IMG_6469.jpg

IMG_6470.jpg

IMG_6471.jpg
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the thick blue smoke; would think it comes from "burning oil", could be broken pistonrings or a gasket...

a workshop can do a sylinder-leak-test.
you can smell the coolant expansiontank, if you smell exhaust, your headgasket is broken
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could also be valve stem seals
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(Post Link) post #4 of 17 Old 03-08-14 Thread Starter
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I disassembled the intake system, there was oil leaking by the gasket and variator solenoid, and two intake hose clamps were loose.

I changed the PCV valve (~15€), the intake manifold gasket (Victor Reinz) and sealed the variator solenoid and replaced all the hose clamps.

Now there is still smoke after excessive engine brake, but only a little. The idle became stable, and the engine feels "smoother".
The oil consumption with a lot of highway (~130 km/h) is now ~ 0,5l / 1000 km

I also made a compression test, with these results:

Cylinder 1 2 3 4
Dry 11,4 11,0 8,3 8,3 bar
Wet 12,1 12,1 11,0 10,3 bar
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(Post Link) post #5 of 17 Old 03-08-14 Thread Starter
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I didn't find anything pointing to a head gasket problem, but I will make a head gasket test later.

I'm also planing on a dyno test, to see what's left of the 150 italian horses
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I also thought about that, but there is never smoke after cold start, even after 2-3 days.
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Often, the symptoms you describe of large clouds of oil smoke after re-application of the throttle following a long, steep downhill section (for example) are caused by a faulty crankcase breather system, so you're looking in the right area with the PCV valve I think. Not sure exactly the system on your early TS but I would also check that there isn't a blockage somewhere in the breather system preventing the oil from returning to the sump - this was a common problem on various 12v V6 Alfa engines for example.
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Viktor, although I have a later CF3 engine, how difficult was it to change the intake gasket?
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Quote:
Originally Posted by Viktor164 View Post
I disassembled the intake system, there was oil leaking by the gasket and variator solenoid, and two intake hose clamps were loose.

I changed the PCV valve (~15€), the intake manifold gasket (Victor Reinz) and sealed the variator solenoid and replaced all the hose clamps.

Now there is still smoke after excessive engine brake, but only a little. The idle became stable, and the engine feels "smoother".
The oil consumption with a lot of highway (~130 km/h) is now ~ 0,5l / 1000 km

I also made a compression test, with these results:

Cylinder 1 2 3 4
Dry 11,4 11,0 8,3 8,3 bar
Wet 12,1 12,1 11,0 10,3 bar
Your compression test results are quite low on cylinders 3 & 4, I'd be thinking along the lines of piston ring and/or bore wear. It looks like you're pulling oil past the rings under high vacuum conditions.
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(Post Link) post #10 of 17 Old 11-08-14 Thread Starter
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After these repairs, it did get much better, so there was a problem with the breathet.
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(Post Link) post #11 of 17 Old 11-08-14 Thread Starter
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The only hard part are two bolts, which I could reach only under the car, but I have an aluminium intakebox, I don't know, if the plastic one of the CF3 is mounted also like mine.
It took me an afternoon to change it.
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(Post Link) post #12 of 17 Old 11-08-14 Thread Starter
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Yes, I think this is the main reason for my problem. Apart from this, I have no problems with the engine, I will it repair if it gets worse. Or swap the engine, a good one cost around 200-300 €.
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Quote:
Originally Posted by Viktor164 View Post
The only hard part are two bolts, which I could reach only under the car, but I have an aluminium intakebox, I don't know, if the plastic one of the CF3 is mounted also like mine.
It took me an afternoon to change it.

Thanks Viktor!

I think these bolts are hard to reach on any variant.

I know I need a day for this ...



Aside from that - how did you seal the Variator Solenoid???
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(Post Link) post #14 of 17 Old 12-08-14 Thread Starter
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I put sealant on the recessed edge of the solenoid housing.
See the last chapter of this link:
The cam variator
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(Post Link) post #15 of 17 Old 12-08-14 Thread Starter
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I also cleaned the intake manifold and so the 4 holes for the injectors, now the injectors are perfectly in place.
I'll also change the o-rings (60754003) of the injectors, because some of them are pretty hard. The Bosch ones (1280210711) cost 1,5€/piece, the Hans Pries ones (111 414 015) cost 0,25€/piece.
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After your replies, I ordered the gasket and should be getting my it any day now. Right now, I am in the middle of a test post flush (BG EPR) that seems to cut down some of the consumption, so I might wait another week before I have a go at the gasket. Just might look into the variator solenoid to see any leaks though.
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Quote:
Originally Posted by Viktor164 View Post
I disassembled the intake system, there was oil leaking by the gasket and variator solenoid, and two intake hose clamps were loose.

I changed the PCV valve (~15€), the intake manifold gasket (Victor Reinz) and sealed the variator solenoid and replaced all the hose clamps.

Now there is still smoke after excessive engine brake, but only a little. The idle became stable, and the engine feels "smoother".
The oil consumption with a lot of highway (~130 km/h) is now ~ 0,5l / 1000 km

I also made a compression test, with these results:

Cylinder 1 2 3 4
Dry 11,4 11,0 8,3 8,3 bar
Wet 12,1 12,1 11,0 10,3 bar
Hi!
My throttle body on my gtv 2.0 ts looks exactly like the one in your pictures. My pcv valve is broken, and i cant find it anywhere on the internet. Where did you find it?
Regards
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