I have known I had a small exhaust for some time now and suspected it might from the EGR pipe.



I got it apart finally and confirmed that yes indeed the bellows portion has a crack.


I was hoping I might be able to cut off the bellows portion and use a small version of something like below to give me a little more flexibility and some wiggle room on the length of the pipe. Ever since I installed the twin screw is is pulled quite tight and it is maybe not too surprising that it eventually failed.



But the pipe is a sort of odd size and seems to be 16.5mm OD (0.65 in). I have not found any flexible exhaust pipe that is so small.

So I am hoping to draw on the collective experience of the forum, what ideas do you all have? How might I be able to solve this one (short of a new OEM pipe which I suspect would eventuality fail the same way)?

 

A quick search turned up this.

Flexicraft Braided Metal Hose Flexible Connectors

​​​​​​They seem to have flexible sections in the appropriate size range.

 

When I thought mine might be leaking I considered having it welded. But luckily mine was not leaking so I never had the chance to try

 

I would have a look into a soft version of welding like brazing/soldering as the walls seem pretty thin. Maybe reach out to a local air conditioning or plumbing company, some of the old timers have some good skills for this. This is a pretty expensive part new, and a junk yard part may be pretty far gone as well. For something to try at home, get copper pipe soldering and a MAPP gas torch from the hardware store. Worst case, you can melt the solder and remove it if you are not satisfied. The part is all metal, and off the car already, so there is no risk to overheat and burn something else. I would resist any type of magic goop as it could possibly loosen up and cause more damage in the EGR valve. I would also try and avoid cutting that section off as it would be hard to find the right orientation again. Just my thoughts, I have not done this myself.

Best of luck, keep us posted.

 

What car is this on????????????

It matters because there was a SERVICE ACTION for some and a DELETE for others. (I hate mystery cars)

bob

 

I do not know this pipe. Is the corrugated bit plastic? You say its from the exhaust? Does it get hot?

I ask because I had a similar problem on my car with such a corrugated pipe. I used electrical shrink tubing on mine. Black. Slid it on. Heated it up. Sealed fine.

Have a read, let me know if you find it useful. Click Me To Read If you scroll down the page you will see the fix.

 

It is from a 2003 XKR. The same one that has been listed in my signature for the last 8 years. That little blob of text at the very bottom of the original post.

Now that the mystery is solved... there is no delete option for a 4.2L to my knowledge, at least not one that won't make the ECU unhappy.

 

By appearance it looks to be stainless steel. And yes, it will get quite warm as there are spent exhaust gasses passing through it. One end it bolted to the right side exhaust manifold.

 

Check out what Fellow Forum member xkr_dougie did. Link below. Post 27 onwards in his ongoing thread. His repair is detailed in post 34.

https://www.jaguarforums.com/forum/x...-217805/page2/

 

Thanks! That looks promising.

 

SORRY! My bad.

I saw the big pictures and the description in between but not the bottom signature.
bob

 

Charlie,

I went through this Problem a couple years ago and tried a couple things like Brazing & Soldering, but in the end I wound up buying a new Pipe from Jaguar....That is my suggestion as it works....Mine lasted from 2005 to about 2018 and I expect this new one to last even longer as I don't plan on messing around with the Exhaust Manifolds anymore..... After all "It was made to do the job'"...…….

Billy Clyde