Hi all. I was recently driving the van and suddenly there was a strange noise coming from the engine. When you start to drive off you can hear the turbo whistling away, as soon as you change into 2nd gear and put your foot down the engine sort of growls. There has been no lack of power. I thought that it could be something wrong with the exhaust so called into ATS and they put it on the ramp. They noticed that the heat shield skin that is wrapped around the main box had come away and that it was probably causing the sound with the air passing underneath. I cut away the heat shield. There were no other problems with the exhaust system. However the growling from the engine was still there when you put your foot down from 2ng gear up. Last friday morning I serviced the van changing the fuel/air/oil/pollen filters. When I changed the POLLEN filter I could not believe that the fillter was completely covered in soot deposits. It was so bad that when you shook the filter you could see a cloud. I put in a new white pollen filter and then drove from Cornwall to Dublin and back covering approx 900 miles in 3 days. When I got back I checked the pollen filter and was aghast to see the underneath of the filter was black. I have noticed over the past few months of smelling fumes inside the cab. (some of you may remember that I did have to replace the roof grey headlining trim some time back due to soot coming in through the air ventsand settling itself on the edges of the trim). I have had no warnings on the dash or error codes coming up. I used to get 40pmg but this has now dropped to about 28mpg The van has done 112,000 and regularly serviced. The only thing that I can think of is exhaust gases coming back into the air system. The Turbo is working fine, which leads me to think that it could be the EGR Valve ??? I would be grateful for any advice:bang:

EGR stuck open can generate a ton on soot and clog up the intake. However the smoke should be contained.

Did they actually take off the exhaust and inspect it?
Sounds to me like the cat might have collapsed or dpf clogged if it has one.

Thanks for the reply. I hae checked with fiat and they told me that if it has a pollen filter with air con then it does have a dpf. Can you tell me where it is?

I finally bit the bullet and took it to fiat dealership. Put it on examiner but no fault codes found except minor one for the air con which needs to be re-gassed anyway. They took it out on a road run for 20 mins. Informed me that it has nothing to do with EGR or Turbo but that the gearbox is on its way out. Now looking at about 3 grand for a gearbox. The van has only done 112,000 Will have to look on ebay.

So let me get this right the cause of the sooty deposits was the gearbox?

tommytopgun said:

So let me get this right the cause of the sooty deposits was the gearbox?

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What he said ^^^

Actually that's not what he said. The way I read it they didn't find a cause for the soot/growling noise but did think the gearbox was on the way out.

If a mechanic couldn't find the source of copious amounts of soot I wouldn't think much of his ability to diagnose a gearbox.

Did the exhaust guys actually remove the exhaust to check it for blockages this would account for all sort of noises and the soot, otherwise the growl is unrelated and maybe your exhaust manifold has split.

If there is an exhaust blockage and you continue to drive it you could end up needing a turbo and a head gasket or a new head.

Just to clarify a couple of points: Went to Fiat dealership as there were soot deposits coming into the cab via the pollen filter, and a grwling noise when changing gear. When the van came back from a road test the mechanic informed me that the gearbox was on its way out. When the van was at traffic lights you can press the clutch down with it in gear and the engine will rev smoothly, but when you release the clutch to go forward it growls.

When the van came back to the garage I asked them to put it on the examiner and there were no fault codes for the EGR or turbo and this would not cause the soot deposits anyway??????. The old pollen filter that was removed last week was caked in black soot. Put in a new pollen filter which is now black on the underside.

I still think that the EGR valve is either sticking open or the DPF Filter may be blocked. Would be grateful if anybody could tell me where the DPF Filter is.

To sum up: Paid £54 to hook up to examiner to be told nothing to do with EGR or Turbo causing soot deposits in cab and that the gearbox is on its way out. Fiat want near on 3 grand for new gearbox. Just about to leave Fiat garage when I remembered to ask again for about the 10th time in 3 years when I can get an engine cover for the 3ltr 160 only to be told again that there isnt one, only available to the 120 & 130. Given up on that now as the injectors look rusted in.

Saw a rebuilt exchange gearbox on ebay today for £1740. Rang the firm and as soon as I mentioned the symptoms they said straight away the it was the gearbox??? Was informed that they tend to sheer off a couple of teeth, but at the moment all gears change smooth with no crunching at all.

Now going to hang myself.

My 2008 3L 160 has an engine top cover.

Was it on from new or did you have to ask for it ?

I bought it at 2 years old and it was already fitted. It has three inserts on the underside which push down onto pillars with a ball on top. It is simple to take off by just pulling upwards near the oil filler where there are two pillars and directly opposite on the other side where there is one.
In my opinion it is off little use as a way of preventing water getting into the injector channel if the scuttle leaks. On the two X250's I have owned I have removed the scuttles completely and then refitted them incorporating some modifications. When done barely any water gets in.
I am no expert but are you sure that the Euro 1V engine has a DPF?

Finally sorted the growling from the van. Turned out to be the main bearing in the gearbox which is going to cost an arm and a leg. Could not believe a new clutch will cost £330 for the 160. Not much change from £1500 to sort this out. The soot deposits did not come in from the air system but was seeping in through drivers door, as the rubber seal was perished at the bottom. Before anybody asks it was getting in when I park up in a layby to get an hours kip when I am doing a long run, the engine is left running to keep me warm.

Pasty007 said:

Finally sorted the growling from the van. Turned out to be the main bearing in the gearbox which is going to cost an arm and a leg. Could not believe a new clutch will cost £330 for the 160. Not much change from £1500 to sort this out. The soot deposits did not come in from the air system but was seeping in through drivers door, as the rubber seal was perished at the bottom. Before anybody asks it was getting in when I park up in a layby to get an hours kip when I am doing a long run, the engine is left running to keep me warm.

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An eberspacher would be a good investment for you I think, that or a jumper

Seal on the drivers door doesn't explain the amount of soot you're talking about accumulating on the pollen filter in 3 days .. and neither explain the 30% loss of mpg if the gearbox was absorbing that kind power the gearbox would have melted by now. You have another problem