Exhaust Smell Problem

[mora2818]

So sometime ago guessing about 4 months when it started getting colder when I turn on my heater it smells like exhaust when my Pathy has been running for a minute or 2 and when stopped. So basically everytime I hit a stop light I would get the faint smell of exhaust.

 

My engine was also making some fairly annoying knocking noises and from reading on the forums it sounded like the famous exhaust manifold problem. So I take it in to a local muffler/exhaust shop in town that is known for being a pretty good company and have them take a look. Yup Drivers side exhaust manifold leak. $300 at least to fix unless it is cracked or studs are sheered off, etc.

 

After searching for the possibility of doing some kind of legal and cheap header setup it was my only option to get the manifold fixed. I had this done 3 weeks ago however the exhaust smell still is there. Mind you the manifold was cracked so the fix ended up about at $500. I thought it might be the paint finish burning off however after 3 weeks of driving everyday I would imagine that would have burned off by now. The thing is when I rev the engine with the hood up it isn't like it is billowing out and however you can definetly smell the exhaust although not much. What I do smell from outside hovering over the engine is about what I smell on the inside as well. Annoying but not gagging you to death.

 

At this point I am not too happy so before I go back and start asking questions and getting fired up if figured I would ask could the problem be something else? Maybe the smell is normal for the engine but the seal from the hood to the HVAC is bad and needs replaced? Oil leak and burning that I am not aware of? any ideas or is it back to the exhaust guys.

 

Sorry for the long write up,

Thanks Kevin

[88pathoffroad]

Sounds like an O2 sensor or EGR line didn't get plugged back in all the way. Do you hear a leak under the hood anywhere?

[mora2818]

I don't hear anything out of the ordinary but I am not sure I know what to listen for.

[94 Pathy]

I have a faint smell like that also. I think it's from having my exhaust ending under the rear seats & I have a tear in my transfercase shifter leather boot. I think the smell is lingering in that way. I'm sure the Pacesetter headers I installed aren't sealed 100% like they should, but preatty darn close.

 

Isn't there a sealant out there where you can run a bead around the headers/manifolds and the heat will help seal the sealant into the groves that aren't sealed by the gasket? Maybe I'm smokin' something?