Alfa 159 EGR valve

[Lead]

My 159 2.4JTDM recently suffered a failure of its EGR valve which left me immediately with no power. Fortunately, I was on a minor road so was able to coast from 30 mph to a safe halt. I had the car recovered to my Alfa main dealer assuming that this fault would be covered under the extended warranty that I took out when I bought it in April. I am advised by the dealer that this is a common fault but would not be covered.

Two questions now arise;-

1) Given that this is a known fault why have Alfa not recalled the cars to relace the valve? It scares me to think what would have happened had this occured on a motorway.
2) Why Alfa will not cover this under a main dealer extended warranty as I am now over £200 out of pocket?

I really feel that this is something Watchdog should investigate from a safety perspective but would like your advice on this matter before I consider taking it further. Thanks in anticipation.

[Rochester TVR]

I suggest you change your dealer. I had the EGR valve replaced under warranty without me even asking for it. I had booked it in becaus e it started to smoke a little on start up, problem is now fixed and this was one of the items replaced.

I use Lipscomb Alfa Romeo in Aylesford, very good service so far and have never questioned anything needed doing under warranty.

[RicksAlfas]

I've had at least two EGR valves replaced under extended Alfa warranty with no problems so I'm surprised at your dealer's reaction. I've never known an EGR valve cause a massive and instant loss of power though. I wonder if it triggered "limp home" mode?

[Lead]

Hi Guys, Thanks for the responses. Rick - It was not in `limp home` mode as each time I restarted the car and took my foot off the brake and placed it onto the accelerator the engine just died. I will recontact my dealer to see if they can cover the costs as others appear to have been successful with the same problem.

[wrinx]

Complain to ARUK if you don't get any joy with the dealer. Unfortunately there are a few issues with the 2.4 engines which Alfa know about but are reluctant to acknowledge or pay for...inlet manfold being another one of them!

wrinx

[wrinx]

Well well...our Brera has now died, the EGR valve (or something near it)is emitting a high pitched whistle...perhaps related?

Battery is off atm to try a reset but it's so cold could something have seized???

Edit: Had it flatbedded to a garage today, diagnosis is knackered EGR

wrinx

Edited by wrinx on Monday 20th December 18:44

[Lead]

Since my original post I have established that under the Alfa second hand warranty that came with the car is the standard warranty rather than an enhanced one. Having spoken to Alfa customer services they have agreed to refund the cost of the part (£90) but I am still out of pocket for the labour. This was probably due to the relative low mileage 29K.

[gary_de_tam]

Re-living this link, my 159 2.4 JTD just decided to fail it's EGR valve according to the garage,
I had no reduced power option as the car just died totally...

[davebem]

The EGR valves are quite straight forward to remove and clean, they normally get blocked up with all the soot. There are guides on the alfaowner forum on how to remove clean and/or replace. While its off fit a restrictor plate (Alfa dealers sell one for the 1.9, not sure about the 2.4), or better still a full blanking plate.

[alpha channel]

Isn't a re-map required when blanking off the egr valve?

As it stands a wee bit of maintenance does these things wonders, I've cleaned the egr body on my own 159 (for the second time this year) last weekend as I had noticed a bit of throttle lag, fifteen minute later and 3mm of soot scraped off the egr body and all's well. Lags gone and power delivery is smooth as butter again and it seems to have picked up a bit of power as well (the sucker is due the whole belt/water pump number as well, might as well get it serviced while it's at it).

[Oilchange]

No remap required on my wife's Rover 75 diesel which is blanked off. Throws up a code when interrogated apparently(OMG! WGAF...) but otherwise it means no daft blockages of the inlet tract with mechanical things that get covered in pointless soot.
Result.

Next job, de-cat.

[suss100]

I have owned my alfa 159 2.4jtdm since March 2014.I had the car Terra cleaned and I had problems there after. My
Car was taken to Motor Mech in Birmingham who did a remap and egr valve delete . I fitted the egr valve blanking plate myself and cleaned out the throttle body which was gutted in soot. Since then I have fallen in love with my 159 2.4jtdm.