Where can I buy Alfa 147 sills?

[BrokenBiker]

Haven't tried Anything with it yet, will try checking the mass air sensor and check all vacuum hoses to the valve solenoid etc.

What will unplugging the egr do?

 

[dobbslc]

The egr valves get clogged really badly with soot and will eventually jam up. (The one on the zafira caused a loss of power below 2000rpm then wham! everything at once. this was the waste gate staying open for too long loosing boost)
As all the different systems are interlinked to each other one going wrong can cause some weird and wonderful faults!
Check the egr for crap build up, check the boost sensor as they get dirty too, and again all the vacuum hoses. You can blank off the egr valves without problems on pre (I think) 2005 cars, the later ones can tell what you've done and light up the dash board with fault warning signs.
I can ALMOST see why VW cheated the system as all this emmisions crap is a nightmare, Almost!
You're lucky you don't have the 16 valve engine.......

 

[BrokenBiker]

Interesting, that could be somethin to do with it. Doesn't feel like turbo kicks In till 3.5k sometimes and others it feels like it's on boost at 2k so might be that. Will have to have a look in the morning and go through everything one by one

 

[dobbslc]

Split in the same place then

 

[BrokenBiker]

Might get the manifold and egr off tomorrow, check sensors etc and if that doesn't help will check vacuum hoses and solenoid valve etc.

Also, what noise should a turbo make? I know all the big turbo's whistle when they spool up but mine sort of whistles with a sort of burble to it. Only noticed it the last few days but I can hear it over the radio and the engine (which isn't that quiet when it's high up the revs)

 

[BrokenBiker]

You mean the exhaust flexi?

Providing it's dry tomorrow I will be spending most of the day tinkering with it so will check then.

 

[BrokenBiker]

Will bear that in mind, probably after I have smashed my knuckle 3-4 times I will remember it lol.

Well I have a list I things to check now.

How to I check if the waste gate is working properly? I assumed I would be able to see it actuating but it doesn't appear to move

 

[BrokenBiker]

No worries. I may replace it anyway as its a 2003 car and been serviced only a handful of times. Cam belt needs doing too so might roll it all into one job after xmas

 

[the snooper]

The waste gate is on the turbo I've not seen the alpha ones some are servo operated some vacuum there should be a linkage from one of the above to it you should see it moving if not disconnect the linkage and check operation by hand, the early mk3 mondeos used to seize and you would end up with no Power

 

[BrokenBiker]

In that case it sounds like it is working as I'm getting all the power I want until the light comes on and then it's in limp mode and feels like there is no turbo so maybe a dodgy sensor?

I think mine is vacuum operated based from what I have been told above

 

[the snooper]

In that case it sounds like it is working as I'm getting all the power I want until the light comes on and then it's in limp mode and feels like there is no turbo so maybe a dodgy sensor?

I think mine is vacuum operated based from what I have been told above

Still worth a check to make sure it's not seized closed

 

[BrokenBiker]

Well I am already not a fan of working on this lump, too much pipe work in the way.

I have located where the egr pipe comes off the exhaust manifold, but can't quite see where it goes.

I have fount the vacuum hose on the waste gate but again can't quite see where it goes and have also found that the pipe from inter cooler to inlet is wrapped in gaffer tape where it joins to the inlet. Also putting my hand over the intake pipe ( before the air cleaner) doesn't starve the engine so may be a leak somewhere.

Where do I find the vacuum pump? Is it on the side of the head above the water pump?

I have traced a rad pipe back to what I think is the water pump and there is another pump like object above it, looks like it's connected to the cam shaft?

 

[dobbslc]

That's probably it on the end of the cam, If the 8 valve is similar to the 16 valve, it should have a pipe going to a solenoid that then has another pipe going to the waste gate. The solenoid on my car was hiding up under the front wheel arch!
Check these very carefully as a tiny split will cause problems.
The intercooler pipe needs replacement by the sound of it, the sensors on the intake side of things won't like a reading that they don't expect.
I would try these things first then clean the map and boost sensors before taking apart exhaust /intake manifolds wastegates etc.

 

[BrokenBiker]

Right, well there is one lone pipe coming off the vacuum pump and it worms it's way into the firewall from what I can see. I will have a look for the solenoid after lunch as the floor is soaking.

Also going to replace te intercooler pipe.

While having a look I found a vacuum operated lever on the side of the throttle body that kills the engine when it's fully depressed and feels like it's cutting off the air supply. What is this for?

 

[Gareth_16V]

Right, well there is one lone pipe coming off the vacuum pump and it worms it's way into the firewall from what I can see. I will have a look for the solenoid after lunch as the floor is soaking.

Also going to replace te intercooler pipe.

While having a look I found a vacuum operated lever on the side of the throttle body that kills the engine when it's fully depressed and feels like it's cutting off the air supply. What is this for?

The throttle won't be used for normal engine running, in the same way as a petrol, it will be used to create a partial vacuum in the manifold to drag more EGR through the system at low loads, when there's not much pressure in the exhaust manifold.

 

[BrokenBiker]

Just plugged laptop in as managed to trigger the light again and it is now saying over boost valve invalid signal ... That sounds like a sensor fault? Where is the over boost sensor likely to be? On the turbo, the waste gate or somewhere else?

 

[BrokenBiker]

The fault code is :

P0236 - overboost valve - signal low - fatal - light on

 

[BrokenBiker]

EGR pipe shouldgo around the right hand side of the block, through a cooler and around the back of the block into the EGR itself

Boost aka MAP sensor should be on the rear of the rocker cover, usually to the left of the EGR, electrical plug and held in by a single torx bolt - it will more than likely need wiggled out as its prob jammed in with sludge

Right, so my car has an electric egr valve and I saw the sensor on the rear of the rocker cover earlier, so would that be the faulty sensor? It also flashed up an egr fault code but didn't put the light on for that one

 

[BrokenBiker]

Will blanking it not cause problems with the Ecu though?

 

[BrokenBiker]

Is this the right sensor?