Exhaust Leak Help

[CREGAN]

Like the title says I have 2 questions for you all.

1) I am getting a really strong deisel exhaust smell coming in the cab through the vents when I am stopped. Do I have an exhaust leak somewhere and how do I check or where would YOU check first? I thought one of the culprits would have been my blanking plates on the EGR as I used some really old silicone the first time on the intake manifold, so I redid it using a new tube of copper silicone. Should there be a gasket on the intake side? Anyway, the smell was almost making me cough today and it was making my little 2 year old cough.

2) I recently had the ATF changed out and I want to check to see that the level is good. I heard that you have to have the engine running on level ground to check. Is that true? Also the dipstick has 4 little triangular notches on it and near the top one it says "HOT". Which notch should it be at or between?

Thanks for your input guys. I know it has been at least a week since I asked for advice, so I hope you all didn't miss me too much

Craig

[jessef]

We always miss you brother !

Warm engine, shift through all the gears and then park it on a flat level to check the oil level.

Triple check your rear door and windows to ensure they are sealed and not letting in exhaust gases as that's the most likely area's that suck it into the passenger area.

EGR planking plates both on intake and exhaust side should be clamped down with a gasket.

[thedjjack]

plug the tail pipe when cold starting...

Look for clouds of black smoke leaking out of the system (diesel are good for finding leaks)

[CREGAN]

plug the tail pipe when cold starting...

Look for clouds of black smoke leaking out of the system (diesel are good for finding leaks)

Are you for real on this one or just pulling my leg? This sounds like the stuff cartoons are made from

Craig

[thedjjack]

just put your foot over the exit (does not need completely plugged) little back pressure an the exhaust will go out the easiest spots....


cheers

[tonydca]

just put your foot over the exit (does not need completely plugged) little back pressure an the exhaust will go out the easiest spots....


cheers

Never tried this on my van, but on my old Toyota if there was *no* leak, after about 10 seconds of sealing the end up tight, the building back pressure would start to make the engine sputter and want to stall.

*TIP* do this on a cold start to avoid having to explain weird burn marks to spouse.

[CREGAN]

Today I took the van out with the family to do some cruising and the smell of exhaust was so strong that it was making my eyes water and my throat sore! When we got home I crawled under the van and traced the exhaust back from the engine and inspected it. Checked all windows and tailgate and they are sealed. It looks OK underneath but something has got to be leaking somewhere because when I turn on the interior fan it just pumps it in from the front of the van. I haven't tried the cold start/blocking the tail pipe trick yet but I am wondering if it would be wise to take it in to a muffler/exhaust shop and have them take a peek. There is no smell when I turn off the heater and fans but it gets pretty chilly. The exhaust only comes out of the driver side of the engine right? I wonder if a gasket is fried or something because eveything looks OK with no obvious holes and the usual heat corrosion on the connections. What do you all think? I will try the cold start trick tomorrow and crawl under again to see if anything shows itself.

Craig

[jessef]

Reminds me on my westy vw days! Exhaust leak that gets pumped throught the vents.

Your fresh air comes in from the front and if it's stronger when you have your vent on you definitely have an exhaust leak in the engine bay. The tail pipe trick will help you visually trace it.

If you can't find it, remove the clutch fan (only to find the leak) so it doesn't blow air everywhere in the engine bay and use baby powder or talc on the exhaust manifold/joints and start it up. See where the leak is by the puffing of the talc.

Your other option is to have an exhaust shop trace it for you.

[Artacoma]

I would check the gasket that connects the air ducts on the hood to your heater as well, above the battery.

[CREGAN]

Hey - I have been brainstorming and had a chance to look over the van and I noticed a few things. I am on holidays right now so I won't be able to do squat about it for a couple weeks. My dad and I sniffed around the engine bay before I left and could not really smell the exhaust fumes on the exhaust side of the engine with the hood open, BUT it was obviously coming in the vents inside and it was super strong. I thought this was weird. Is there any chance that the intercooler would be leaking and the fumes are being sucked right into the intake since it is in that location? The intercooler does have exhaust filling it right? Anyway - just brainstorming because I want to solve this as soon as I return.

Craig

[psilosin]

Your intercooler should only have intake air not any exhaust.

[thedjjack]

another thing that you can try is getting some hose like heater hose hold one end to your ear and then poke it around the turbo, manifold, head, etc to listen for leaks....

[thedjjack]

I would also check around the manifold gasket, turbo (smallest leak on my Escort filled the car at start up with pre-warm converter smelly exhaust)

Also, make sure it is not an oil leak that is smelling like diesel burning off the manifold or something

[CREGAN]

Alright, I have been out of the country for a couple weeks but am back now to sort this exhaust leak out. I did some serious sniffing all around the engine bay today and have tracked the smell to be at it's strongest concentration at the top middle of the intercooler, which is right by the cabin air intake. I know this may have nothing to do with finding the leak as I do not know how to stop the fan from blowing, so it could just be blowing the fumes there. Definately a leak somewhere inside the engine bay. Any ideas now, if this helps? I am a one man show here trying to get this sorted so I have not been able to plug the exhaust and watch for the leak- might try to get the wife to help me out (probably not going to happen). The smell is definately strongest when it is just sitting and idling. It smells so strong it is as if you have the exhaust directly piped in to blow in your face. When I am driving at any speed it does not blow into the cabin as bad. I really don't know what to do, and now my wife has decided she doesn't want to ride in it anymore as the smell is so strong. I have to sort this out. If I take it to a muffler/exhaust shop do you think they would know what to do (tracking it down) and where to look without trying to rape me? I am thinking that if I can just locate the leak I can try to fix it myself.

Craig

[Rising Sun Auto Import]

I would suggest to have a pressure test for your cooling system while engine running.
As you know, we have a coolant expansion bottle ( very fragile ) and heater bleeding screw around your pointing spot.
I remember you had a hard time for TPS or tranny issue as hard driving maybe led to exhaust gas into coolant.

Just my thought.

Steven