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Is your problem SOLVED? Please help me! I have the same problem. The engine compartment completely smells of exhaust gas. It is clear that the exhaust gas is leaking somewhere. They checked it at two service stations, but no leaks were found. Can you help?
Yep, I'm on my third manifold now. Always cracks at the EGR return elbow/manifold flange weld joint - always!. Number three has now failed and i'm going to weld up the last one myself with some reinforcing gusset. The crack is so fine its hard to see, but a smoke test up the exhaust pipe should reveal it.
The manifold is removed from above
, Disconnnect the plastic turbo hoses,
Remove metal bracket mounted to turbo that bolts to head
Unclip dpf sensor connectors (3)
remove bolts holding upper heat shield (3)
Undo 3 bolts holding DPF to turbo
Undo 2 12mm head size bolts under turbo holding it to a bracket ( not visible)
Undo 3 Bolts holding turbo to manifold
Remove turbo oil feed and return pipes.
Remove turbo
Undo bolts and nuts holding manifold to head
On the left side of the manifold the outlet to the EGR port is smaller. This is where it cracks all around the pipe. You will see black soot on the left side of the manifold
You can remove the lower DPF mounting bolt to make things easier, but this is only accessible from underneath.. This bolt secures the DPF to the transfer case.
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IGetting it rewelded is preferable to JB weld. I have never personally tried it
I agree, I've done something similar myself and re-welding helps.
Last edited by 24901049; Nov 30, 2023 at 09:04 PM.
Yep, I'm on my third manifold now. Always cracks at the EGR return elbow/manifold flange weld joint - always!. Number three has now failed and i'm going to weld up the last one myself with some reinforcing gusset. The crack is so fine its hard to see, but a smoke test up the exhaust pipe should reveal it.
Hi, Another one with the same problem. 3rd time..wow! When the manifold was replaced how long was it before the issue started again?
Love the car but debating on trading in due to this issue.
Thanks
Exhaust gas smell in the passenger compartment
