Giulietta Exhaust Flap Issues Cause Loud Start-Up

I had a very similar issue with my 2019 Giulia diesel last winter. I have some experience working on cars but exhaust systems are not my specialty. The symptoms matched exactly what you describe, loud exhaust noise and error codes related to the exhaust flap actuator. The flap was getting stuck and not responding properly to the control signals. After a thorough inspection, the workshop found that the flap actuator had failed due to carbon buildup, which is a common issue affecting engine performance. The repair involved: Complete removal of the exhaust section, Replacement of the faulty flap actuator, Cleaning of the exhaust valves, System reset and testing Total cost was 190 Euro and took about 3 hours to complete. The exhaust blockage issue was resolved and the noise returned to normal levels immediately after. Could you share: Current mileage on your Giulietta, Exact error codes you are getting, How long has the noise been present, Any other performance issues you noticed This would help determine if your issue is similar and whether you might need the same fix.

Just had mine fixed a few days ago at 102811 KM. The flap actuator was completely seized due to carbon deposits, causing constant exhaust noise. After cleaning the exhaust valves and replacing the actuator, the noise disappeared completely. The fix restored normal engine performance and proper exhaust system function. It cost 240 Euro for parts and labor. If you want, I can check my service invoice for the exact part numbers.

Thanks for sharing your repair experience, it really confirms what I suspected about these flap actuator issues on our Giulias. The carbon buildup problem seems quite common around the 100K mark. My repair costs were a bit lower at 190 Euro, but the fix was essentially identical, cleaning the exhaust components and replacing the seized actuator. The workshop mentioned these flap motors often fail due to carbon deposits, especially in diesel models. One thing I noticed after my repair, the cold start noise completely normalized and the engine running sounds became much smoother. The exhaust repair also seemed to improve overall performance, probably because the exhaust blockage was cleared during the service. My only suggestion would be to have the exhaust valves checked and cleaned during regular services to prevent another flap actuator failure. Since having mine fixed last winter, I haven't had any exhaust-related issues return. Those part numbers could be helpful for others facing similar problems with their exhaust systems.

The repair was exactly what I needed, thanks for sharing your experiences. Good to know the cost range is typically between 190-240 Euro for this type of exhaust flap repair. Here are the part numbers from my service invoice for the flap actuator replacement: 156A890 for the motor assembly and 156B443 for the gasket kit. The workshop said keeping the exhaust system clean is key to preventing future flap motor failures. Since the repair, my cold starts are completely normal and the annoying exhaust noise is gone. Engine performance is noticeably better too, probably because the exhaust can flow properly now. Will definitely get those exhaust valves checked regularly during service to avoid another seized actuator. Really appreciate all the detailed feedback from everyone. It helped me understand exactly what needed fixing and what to expect cost-wise for the repair.