D2.4T Exhaust leak
 

Hello there. Upon start up I am noticing an exhaust coming out on the engine near the intake manifold. There is a noticeable amount of soot on the side of the intake manifold above where the exhaust is coming out. What may be causing this leak? Thank you.

somebody got one of the exhaust gaskets in backward, or a few of the studs holding the manifold in place have broke or fell out form not using the proper copper locking nuts.

Maybe other sources if you have EGR.

Can you get an exhaust gasket in backward and still bolt the intake manifold on? I think that's what their asymmetrical profile is all about. I have never tried it but IIRC if you get one in the wrong way it wants to overlap with the intake manifold gasket.

Typically you will hear some extra exhaust noise if it's an exhaust leak upstream of the turbo -- a shrill whistle or chuffing sound if it's one of the header gaskets. Notice any changes in sound?

If you're able to take a picture and post it here, will probably make it easier to get ideas for what and where the problem is.

They will go in with some permutation of upside down/backward, one in my car was like that, and it leaked only a little, but blocked about 1/3 of the port IIRC.

exhaust leak
 

Hi there. Thank you for the replies. I believe the emissions have been disconnected. I will take a photo of the engine as there is a noticeable amount of soot on the intake manifold. Seems like the overall sound is getting pronounced as I will also inspect the muffler system as maybe there is also a hole in the silencer(s) or pipes. Thank you.

Exhaust Leak
 

Attachment 283


Hello there. When I start the engine up in the morning, some exhaust is leaking out under the intake manifold. Kind regards.

http://www.d24t.com/attachment.php?attachmentid=283
Looks like a bad gasket on the EGR pipe at the manifold

Exhaust leak
 

Hello there. Thank you for the response and the help. Any ideas where I may source the parts needed to do the repairs? Thank you again. Regards,

Wherever steel plates about 2" long are sold.

or try no gasket and a little orange RTV
look in tascavolvo online catalogand see if you find anything
If not, maybe VW 038 131 547 A (ALH TDI EGR gasket manifold-tube) and 069 131 547 D(tube to valve)
I could see having to trim the bolt holes, but It seems like they'd be close enough to work.

Exhaust leak
 

Hello there. Yes there seems to be a blown egr gasket. a big chunk has blown out in the centre area of the egr. I may remove the exhaust manifold as well as there seems to be quite a lot of smoke on the start up on cold mornings. Thank you.