Ok. This is a follow.up

For a longrunning problem with the 1.3 mj in a Grande Punto.

Car bought in fair condition.. no service history.

Used for local travel.. on an occasional basis (thankfull no DPF..)

9 MONTHS after purchase did a 2 hour m.way journey.. almost gassed ourselves...

Lots of fumes in cabin.

The car had had the occasional whiff.. but nothing too bad on short trips.

Thankfully I own an almost identicsl sister car.. so know when something is amiss.

Had the basic exhaust checked = fine

So had a grovel around underbonnet..

Access isnt great..
So took photos at rear of motor..

Comparisons:
One shiny
One sooty


Time to investigate..!!

As you could probably see..

The clip wasnt on straight..
Hardly surprising.. as you can SEE Nothing

After several attempts of :
Remount clip.. take photo


It became obvious there was a problem


The steel tube had been crimped by the clamp (as designed)

But with the tube out of square.. oops

So of course now its too small in ots 'crimped ' form.. to actuall mount up properly..

A temporary extender tube:
Coke can and jubilee clip

Made the car driveable.. but not right.

A scan of ePER scared me .

EGR €650 thats the pipe in question

BRIGHT IDEA.. the mating flange : stub

Is much simpler
STILL EXPENSIVE €65

So I will try and dismount the stub..

Swage out the tube..

And mate the 2 properly.. then bolt the stub back into the manifold

But the bolt heads are mangled..
So wont come off easily

Bit of a bodge but how about some Gun-Gum then try and find a pipe from a scrapyard.
A few turns of steel wire (thin MIG wire or even better stainless steel locking wire) in the Gun-Gum helps support it.


Robert G8RPI.

g8rpi said:

Bit of a bodge but how about some Gun-Gum then try and find a pipe from a scrapyard.
A few turns of steel wire (thin MIG wire or even better stainless steel locking wire) in the Gun-Gum helps support it.


Robert G8RPI.

Click to expand...

No worse a bodge than my coke can..

Biggest issue here is access..or visibility.

Glad its in a gp .. not a panda

varesecrazy said:

No worse a bodge than my coke can..

Biggest issue here is access..or visibility.

Glad its in a gp .. not a panda

Click to expand...

Or a 500 as the scuttle area overhangs the rear of the engine guessing the panda is the same?

Hard to see in the pictures but the pipe is concertinered up on the damaged unclamped pipe, I’d be inclined to remove it and see if it can be stretched out again carefully

AndyRKett said:

Hard to see in the pictures but the pipe is concertinered up on the damaged unclamped pipe, I’d be inclined to remove it and see if it can be stretched out again carefully

Click to expand...

3 hour job apparently..

Im going to use an expanding former to try and swage the end of that hose back to its original.. pre.crimped dimension.
Sounds easy.. but there it very little space for tools..@1cm

Unfortunately the hose appears to be an integral part of the EGR.. around £600

And all out of sight behind the motor