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Discussion Starter · #1 ·
06 plates, 82k miles

I've replaced the timing belt(full kit with rollers and pretensioners) and drove it maybe 3 times and the clutch failed. One of the bearing metal ears that holds the fork (stupid design). So now the car has a new clutch( full kit with dual mass flywheel) and new slave cylinder.

What I haven't replaced is the accessories belt. I'm annoyed that I forgot about it.

Now, the issues.

When I turn the engine off, with clutch pedal pressed or not, the engine has a big shake that wasn't there when I got the car.

In between the belt and the clutch, I did a long drive and all went good.
After the clutch, the same day or the next day, got 3 error codes out of the blue.

At first round, P0401 and P0335, but the car was running okayish, just limited power.
After clearing the above codes, I drove around a bit and at the 2nd round, it threw P0236. Again, car goes, but with limited power.

At this point, my childish grin is gone, but there is hope to get it back

What can it be? What did the mechanic missed? Any sensor or connector missed when putting all in after the clutch change? Battery went out, the hose that goes into EGR went off and God knows what else that is underneath and I don't know.

The guys are super friendly, did really good job on previous car and good at "change only if not able to repair", but not Alfa specialists.

Thank you all,
Vroom vroom and safe trips.

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Could be running on a bit with oil mist from the bottom turbo hose or unburnt fuel if it's running rich.
P0401 is your egr valve stuck closed. Better than been stuck open but worth investigating.
Doesn't sound related to your clutch or belt.
 

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Re the engine shudders - check the vac hoses on the butterfly valve.. In fact check over them all.

I broke my VNT solenoid and had a massive vac leak for a week - had a bug shudder on key-off every time until I got a spare sorted out. Could explain the boost error code too if the VNT isn't acting as it should due to vac leaks.
 

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Discussion Starter · #4 ·
Could be running on a bit with oil mist from the bottom turbo hose or unburnt fuel if it's running rich.
P0401 is your egr valve stuck closed. Better than been stuck open but worth investigating.
Doesn't sound related to your clutch or belt.
How can I test? The hose that goes in the EGR was removed when clutch was done and fitted back. Had some small crack in it, so I taped it until I get a replacement. If I look at the EGR, will I see when it changes position if I run the engine while parked?

Thanks.

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Discussion Starter · #5 ·
Re the engine shudders - check the vac hoses on the butterfly valve.. In fact check over them all.

I broke my VNT solenoid and had a massive vac leak for a week - had a bug shudder on key-off every time until I got a spare sorted out. Could explain the boost error code too if the VNT isn't acting as it should due to vac leaks.
I'm a newbie. Can you please add more details/description to that VNT? Vac is vacuum?

Thanks.

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I'm a newbie. Can you please add more details/description to that VNT? Vac is vacuum?

Thanks.

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VNT - Variable nozzle Turbocharger. There's a set of vanes inside the turbine housing that direct the exhaust flow. Depending on the position of these vanes, the amount of boost pressure the compressor side of the turbo will go up or down.

The position of the VNT vanes is controlled by a vacuum actuator and a solenoid valve.

There's a bunch of small vacuum hoses strung through the engine bay that provide this vacuum - they also operate the anti-shudder valve on the inlet manifold.

A vacuum leak can cause mischief for sure!
 

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Discussion Starter · #7 ·
VNT - Variable nozzle Turbocharger. There's a set of vanes inside the turbine housing that direct the exhaust flow. Depending on the position of these vanes, the amount of boost pressure the compressor side of the turbo will go up or down.

The position of the VNT vanes is controlled by a vacuum actuator and a solenoid valve.

There's a bunch of small vacuum hoses strung through the engine bay that provide this vacuum - they also operate the anti-shudder valve on the inlet manifold.

A vacuum leak can cause mischief for sure!
Thank you. I now need to sit out some engine bay schematics so that I know where I'm pointing my finger.

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Discussion Starter · #8 ·
In a different order, I have torque lite on my Android phone and an Bluetooth OBD2 adapter and I read various values or read/clear fault codes. Any other software that is recommended to have? Can be PC, Mac, Android phone or tablet.

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MES is best diagnostic tool.
Blank the egr with a plate for £10 and then forget about it.
VNT vac hoses can be found by the bonnet catch. They are about 4/5mm internal. Follow them and they are attached to a plunger thing (low down) that operates the turbo vanes. Check it moves when the car is running. When you turn the ignition off you'll hear a buzz then a pop. This is the vacuum being released. You should see the plunger move.

Do you have a sooty back bumper?

P.S. Do some reading on this site as this is very common problem for low boost.
 

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Discussion Starter · #10 ·
MES is best diagnostic tool.
Blank the egr with a plate for £10 and then forget about it.
VNT vac hoses can be found by the bonnet catch. They are about 4/5mm internal. Follow them and they are attached to a plunger thing (low down) that operates the turbo vanes. Check it moves when the car is running. When you turn the ignition off you'll hear a buzz then a pop. This is the vacuum being released. You should see the plunger move.

Do you have a sooty back bumper?

P.S. Do some reading on this site as this is very common problem for low boost.
Thank you. The thing with reading the forum is a good suggestion, but as always, when you're a newbie like me into alfas but love it so much, you want to skip time spent searching and just learn everything as fast as possible. At least that's me right now, acting like a sponge.

To answer your question, there's no black smoke on the exhaust.

I'll get back from work and start troubleshooting.

Thanks again.

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I second that you need to check a condition of VNT vacuum hose. this is a thin hose located literally in the space between the radiator and engine (easily located when the plastic engine cover is removed). Best way is to get silicone hoses and replace them regardless (rubber ones WILL crack at some point). The split might be tiny and not obvious (usually at the end of the hose) but you can feel it with finger tips. Normally they split at the ends.
 

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Discussion Starter · #12 ·
I second that you need to check a condition of VNT vacuum hose. this is a thin hose located literally in the space between the radiator and engine (easily located when the plastic engine cover is removed). Best way is to get silicone hoses and replace them regardless (rubber ones WILL crack at some point). The split might be tiny and not obvious (usually at the end of the hose) but you can feel it with finger tips. Normally they split at the ends.
Thank you.

Do you have a link or part number for those silicone hoses?


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Discussion Starter · #15 ·
The joy! Today, with all the filters and oil change, at a really close inspection, a small hose next to the turbo was found cracked​. Replaced and car runs smoothly.
Thank you all for the advice and support.
I'll start a new thread for next annoying aspects.

Thanks again.

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Discussion Starter · #16 ·
Thank you. The thing with reading the forum is a good suggestion, but as always, when you're a newbie like me into alfas but love it so much, you want to skip time spent searching and just learn everything as fast as possible. At least that's me right now, acting like a sponge.

To answer your question, there's no black smoke on the exhaust.

I'll get back from work and start troubleshooting.

Thanks again.

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I've traveled a bit and didn't got the time to post back. Damn vacuum hose was broken. Now the car runs smoothly as it's supposed to.

Thank you everyone.

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