When I purchased my Fiat Marea last week, little I was aware that It was smoking under normal revs. You could see black smoke particularly at night when other headlights would point from the back. For example, if you are at a set of traffic lights and as soon as you press the throttle, you can see the black smoke. Anyway, I decided to sort this problem out today and so I did and this will be an advice for everyone to tackle this on there JTD engine.

1. Remove engine cover 4 x 10 mm
2. Look for the EGR valve ( it looks cylindrical and 4 allen nuts holds it in place )

I was amazed to see so much black stickly carbon inside. I had to take a soft brush and take all the carbon deposits

I went all the way taking pipes and air inlets out and there was so much sludge, I could not believe my eyes!

All that was needed was a good clean to bare metal. I did this will a soft brush and thinner. This job can get very messy and good protective gloves is very essential.

I cleaned everything in detail and assembled them. Started the engine, no problems. The engine is reving so much better now and yes the black smoke has completely gone. I am happy now.

Hmmm... :chin: ERG valve?

Hellcat, seems like your engine is a 5 cylinder model, even though the EGR valve can be seen on top on th e front manifold. My JTD 110 has got a electronic EGR and it mounted on top rear of the engine. Hope this helps.

You would expect the valve to get 'sooted' up after a while afterall its carrying burnt exhaust gases but yours seems a exceptional case!