23 · Diagnostics

Black exhaust fumes

Make: Alfa Romeo
Model: 159 Factory Service Manual
Year: 2005–2011
Section: Emissions › Black exhaust fumes

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Fault diagnosisBlack exhaust fumes

BLACK EXHAUST FUMES

1.9 JTD 8V, 1.9 JTD 16V, 2.4 JTD 20V

The customer complains of: Excessive black/grey fumes

0	PRELIMINARY CHECKS	All OK	Problems encountered	Operation
		Results of the tests
	Check that the engine oil level is correct Op. 0010T11 ENGINE OIL - CHECK LEVEL AND TOP UP, IF NECESSARY Check that the air intake/vacuum circuit is working properly See Test 1048OA AIR INTAKE/VACUUM CIRCUIT CHECK Check the condition of the fuel supply circuit and make sure that it is working properly See Test 1040OA FUEL SUPPLY CIRCUIT CHECK Check the operation of the low pressure supply circuit See Test 1060OB CHECK ON SUPPLY LOW PRESSURE FUEL CIRCUIT	Move on to Step 1	Oil level incorrect	Restore the correct engine oil level Op. 0010T11 ENGINE OIL - CHECK LEVEL AND TOP UP, IF NECESSARY
1	AMBIENT PARAMETERS CHECK	All OK	Problems encountered	Operation
	Select the following control unit at the diagnostic equipment: EDC16C39 Diesel electronic injection control unit. Check the value of the following parameters: . Battery voltage See Test 5530BB BATTERY VOLTAGE CHECK . Engine coolant temperature See Test 1060OE CHECK ON OPERATION OF COOLANT TEMPERATURE SENSOR . Diesel temperature See Test 1060EA DIESEL FUEL TEMPERATURE CHECK . Engine rpm See Test 1060GI ENGINE SPEED CHECK	Move on to Step 2
2	ELECTRICAL EQUIPMENT CHECK	All OK	Problems encountered	Operation
	Check that fuse F1 has not blown (it is the last one at the bottom of the vertical row) The check on the following system is only necessary if the outside temperature is below 0 °C.	End of diagnosis	Fuse F1 has blown	Restore the connections or, if necessary, replace the junction unit in the engine compartment Op. 5505A13 ADDITIONAL JUNCTION UNIT IN ENGINE COMPARTMENT - R.R.

1.9 JTS, 2.2 JTS, 3.2 JTS

A high level of dark coloured exhaust fumes is noted

0	PRELIMINARY CHECKS	All OK	Problems encountered	Operation
	Check whether the problem is associated with oil consumption	Move on to Step 1	Excessive oil consumption	See table X05 EXCESSIVE OIL CONSUMPTION
1	AIR CIRCUIT CHECK	All OK	Problems encountered	Operation
	Check: - the state of the air filter; - the condition and seal of the air supply circuit	Move on to Step 2	Circuit component damaged	Replace the damaged component.
		Move on to Step 2	Filter element dirty or damaged.	Replace the filter element Op. 1048A14 AIR CLEANER FILTER ELEMENT - REPLACE.
2	CHECK USING DIAGNOSTIC EQUIPMENT	All OK	Problems encountered	Operation
	Connect the diagnostic equipment (Examiner or other instruments) to the diagnostic socket and check that none of the following errors are present in the engine management control unit: (only for 2.2 JTS version) P0130, P0133, P0134, P0135, P0136, P0139, P0141, P0150, P0153, P0154, P0155, P0156, P0159, P0161, P0300, P0301, P0302, P0303, P0304, P0420, P0430, P1135, P1141, P1155, P1161, P1172, P1173, P1175, P1176, P1607, P1608, P2097, P2099, P2237, P2240, P2243, P2247, P2251, P2254, P2263, P2414, P2415, P2416 (only for 3.2 V6 version) P0130, P0133, P0134, P0135, P0136, P0139, P0141, P0150, P0153, P0154, P0155, P0156, P0159, P0161, P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0420, P0430, P1135, P1141, P1155, P1161, P1172, P1173, P1175, P1176, P1607, P1608, P2097, P2099, P2237, P2240, P2243, P2247, P2260, P2262, P2263, P2414, P2415, P2416	Move on to Step 3	One of the errors listed is detected.	Continue following the instructions for the diagnostic equipment.
		Move on to Step 3	No dialogue with the engine management control unit.	Restore the correct connection between the engine management control unit and the diagnostic socket See E5030 PETROL ENGINES ELECTRONIC MANAGEMENT
3	CHECK USING DIAGNOSTIC EQUIPMENT	All OK	Problems encountered	Operation
	Keeping the diagnostic equipment connected, carry out the active diagnosis at the injectors	Move on to Step 4	Connections faulty.	Restore the correct connection for the injectors and the solenoid valve with the engine management control unit See E5030 PETROL ENGINES ELECTRONIC MANAGEMENT
		Move on to Step 4	Injectors faulty.	Replace the injectors Op. 1056F70 INJECTOR ONE R R WITH FUEL MANIFOLD PIPE REMOVED INCLUDES GASKET REPLACEMENT
4	FUEL PRESSURE CHECK	All OK	Problems encountered	Operation
	Check the correct fuel supply pressure	End of diagnosis	Pressure not correct	Replace the fuel pump assembly Op. 1040A70 SUBMERGED PUMP ASSEMBLY COMPLETE WITH LEVEL GAUGE CONTROL - R + R

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