Technical Resealing the Exhaust Front Flange with a new Gasket

[ruttyboy]

Hi all,

I replaced my steering rack at the weekend in my 2001 Mk2 Punto and part of the procedure was to disconnect the exhaust at the front flange (between the exhaust manifold downpipe and the middle section), the Haynes manual hilariously told me to 'recover the gasket' when what it should have said is 'scrape off the rust that used to be a gasket').

After scraping the rust away I found that the two flanges were all bent out of shape (presumably from heating and cooling so many times) which meant that when I went to put in the new gasket it didn't seal completely and there was still a small gap. This gap was leaking a little liquid/exhaust.

The new gasket was pretty soft metal, does anyone know if this will melt a little and mould to fill the gap as necessary?

Also, between the two flanges was a metal ring the diameter of the exhaust, was this a surviving part of the old gasket and so I should have removed it or is it supposed to help seal the connection also? I left it in there but it's not a big hassle to undo it again and get it out if that's the thing to do.

Any help on this will be greatly appreciated.

 

[DaveMcT]

That ring might be why the flanges have bent.

Clean the gasket faces completely with a new gasket and exhaust sealing putty might help. You have to work quick because that stuff soon dries out. Avoid getting clag down the pipe as it wont do the cat much good.

A better bet is to take the pipe off the car, grind and file the flange flat and make sure there is no kak in the pipe or catalyst can. It its really bad replace the pipe.

Ideally use Stainless bolts (much easier to remove in the future) with carbon steel nuts and carbon steel spring washers. Stainless to stainless tends to self-weld and / or shake loose. Lots of good quality copper/moly paste too.

 

[ruttyboy]

Thanks WhiteSei, unfortunately I don't have the gear to grind the pipe, but I might try to get hold of some putty and remove the ring.

 

[sixpotman]

Without the ring gasket it will probably blow anyway
as the flange is bent.

John

 

[Mattg501256]

hi, im experiencing the same problem.
my MOT is due on november 28th 2011, does anyone know where to purchase the front flange gasket ring from. links are appreciated if poss. my punto is 51 plate 1.2 8v 3dr

Cheers

 

[s and b]

here
http://www.ebay.co.uk/itm/FIAT-Punt...arts_Vehicles_CarParts_SM&hash=item415b049179

 

[mbonner02]

all you need to do when you put that metal gasket on is remember to either put copper slip or preferably engine/high temperature silicone because the silicone will seal it 100% hope this helps

 

[Mattg501256]

cheers!

 

[thelad]

Never heard of useing copper slip to seal an exhaust joint.