Whiffy smell in cab, had that, check the copper washers on bottom of injectors for the dreaded black death gunge.
Then Smokey Robinson problem. As too doon the back of that engine, quicker and safer, removing the engine sorry to say. Changing EGR is a pig. EGR Cooler just as bad. Inlet manifold is main problem as some of the bolts are fitted and removed without sight. Why remove manifold, cos mine was full, plugged, with carbon black. Then there was the inlet tracts in head, how does the air get in there with it that bad, scrapper required and vacuum sourse. At start car was going well, excellerating well, but smoking badly.

goggs said:

Whiffy smell in cab, had that, check the copper washers on bottom of injectors for the dreaded black death gunge.
Then Smokey Robinson problem. As too doon the back of that engine, quicker and safer, removing the engine sorry to say. Changing EGR is a pig. EGR Cooler just as bad. Inlet manifold is main problem as some of the bolts are fitted and removed without sight. Why remove manifold, cos mine was full, plugged, with carbon black. Then there was the inlet tracts in head, how does the air get in there with it that bad, scrapper required and vacuum sourse. At start car was going well, excellerating well, but smoking badly.

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Injectors too far down back of engine.??

Ive got the 1.3.. pretty sure theyre on top..

The clogged inlet manifold is a not unusual on diesels which are largely driven slowly or at town speeds. The EGR is running full bore and airflow is not fast enough to keep the inlet manifold clean.

The excessive smoke will quickly wreck any exhaust filter fitted to the car.

Many cars have the inlet manifold so tightly tucked it, its easier to remove the engine for removal of the manifold.

Hi again got caught up in my Oxygen hoses. No the whiffy smell in cab turned out to be the easy job. One injector was noticeably leaking a mess, while other was starting. Thought we would cure exhaust smoke as well by changing injectors but it pays you to just do spill test.
Down back is of course where, inlet manifold stays and EGR. End of inlet manifold removed and this black thingy stuck its head out. That was the start of tedious manifold/EGR removal, cleaning, swearing, etc.. EGR renewed, second hand cooler and MAF.
Did ECU tests with Multilicious (sounds better) and nothing really altered before and after except EGR being open 0.030". (I'll get on here later).

hello, I have 1.3 grande punto, recently had whiffy smell in the cabin, it was the injector seals [I done a guide on here if you look it up], if you can get access to the top of the engine while its running drop some water into the trough where the injectors are, if it bubbles up the seals are gone

levemircento said:

hello, I have 1.3 grande punto, recently had whiffy smell in the cabin, it was the injector seals [I done a guide on here if you look it up], if you can get access to the top of the engine while its running drop some water into the trough where the injectors are, if it bubbles up the seals are gone

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Thanks.

Water in the wells..

See my post in tech section..
its a GP too

Charlie

Sweetsixteen said:

You can see the egr mechanism if you remove the top part - working from above, not underneath - but to clean out the egr is a bigger job, because the whole thing has to be removed.
Not convinced that your problem is egr-related. Sounds more like a leak of fumes into the cabin because of an underbonnet leak.

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All the how to's I read seem to Say :
drain coolant.. then remove and clean the EGR..

BUT can I just unbolt the finned section?

Draining no coolant..

See my pics in Tech section

Thanks

The finned part is just the solenoid. Once you take it off you'll see a small plunger in the end. You can't clean anything just taking that off, you'll have to take the whole egr valve out.

Cinq999 said:

The finned part is just the solenoid. Once you take it off you'll see a small plunger in the end. You can't clean anything just taking that off, you'll have to take the whole egr valve out.

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Cheers..

Not even enough space to gauge crud levels?

Does the coolant definitely all need draining?

Not able to swing it around on hoses?

When the solenoid is removed, you can see the plunger and spring which opens/closes the egr, but no access into the valve itself.

Only way is to take the entire valve out. I also think the coolant pipes definitely have to come off, there's virtually no room to move, let alone clean it.

I had a mechanic take it off along with the inlet manifold soon after I got the car, and it took him several hours. It was such a pain, when the egr died earlier this year, he didn't want anything to do with it.

It would be wise to look inside the inlet manifold with an inspection camera. They can become clogged with carbon which will lead to EGR faults.