New to CRD - exhaust leak issue

mvoss15 · **Posted:** Wed Mar 09, 2011 11:32 pm

I just bought an 05 CRD! Been looking for one for a while, and finally found one that fit our budget and desired spec's. 82K miles, all-in-all runs great. As I have time this week, and the weather cooperates, I'll be completing most of the basic stuff in noob guide - cleaned the MAP sensor tonight - was caked with soot.

In driving it around the last 2 days, when at idle (such as a traffic light) I am getting some exhause fumes sucked into the car. As I was under the hood tonight, I started it up, and could definetly smell exhaust - strongest on the passenger side - I'm guessing maybe a leak at the connection from the turbo output to the exhaust pipe? This area of the engine also sounds much louder (more of a loud exhaust rumble than a typical diesely-sound) which also makes me think that there's a leak here, as it would be unmuffled coming right out of the turbo. Funny thing is - unplugging the MAF sensor (ORM) noticeably reduced the amount of exhaust smell - and reduced the noise (though didn't eliminate it fully).

Ok, so here are my questions - Is this a likely place for an exhaust leak? Or, is something else likely the matter? Any specific other places I should check?

Thanks!

CATCRD · **Posted:** Thu Mar 10, 2011 12:09 am

mvoss15 wrote:

In driving it around the last 2 days, when at idle (such as a traffic light) I am getting some exhause fumes sucked into the car. As I was under the hood tonight, I started it up, and could definetly smell exhaust - strongest on the passenger side - I'm guessing maybe a leak at the connection from the turbo output to the exhaust pipe? This area of the engine also sounds much louder (more of a loud exhaust rumble than a typical diesely-sound) which also makes me think that there's a leak here, as it would be unmuffled coming right out of the turbo. Funny thing is - unplugging the MAF sensor (ORM) noticeably reduced the amount of exhaust smell - and reduced the noise (though didn't eliminate it fully).

Ok, so here are my questions - Is this a likely place for an exhaust leak? Or, is something else likely the matter? Any specific other places I should check?

Thanks!

That sounds exactly like you have a leak in the EGR pipe. When you unplugged the MAF, EGR was reduced, and so was the smell and noise.

mvoss15 · **Posted:** Thu Mar 10, 2011 12:18 am

Hmm...I was beginning to wonder the same thing. Reading through the FSM, but not having much luck in identifying location of/how to get to the EGR pipe. Any tips?

Drewd · **Joined:** Mon Feb 06, 2006 12:24 pm **Posts:** 902

Couple of things to check.

1. Crank case ventilation system. If disconnected or connected to elephant hose mod, blowby gasses stink similar to exhaust.

2. EGR pipe flange has been known to fail and worth a check.

europachris · **Posted:** Thu Mar 10, 2011 9:22 am

If it's only EGR or exhaust related, consider yourself lucky. I chased an exhaust smell for months before finally finding a bad #4 injector seal. The fun part was that the slow leak of soot combined with the drool from the CCV puck on the valve cover running down into the injector bore made a nice, thick goo that impacted the injector quite thoroughly in the head. It took me several evenings of excavation with small picks and long, thin screwdrivers before I finally was able to pull the injector using a tool I fabricated similar to the $300 "official" tool.

A dealer tech probably would have just ripped the injector in half with the puller and then told me I needed a new head, too...... :banghead:

mvoss15 · **Posted:** Thu Mar 10, 2011 9:49 am

Injectors look pretty clean, but, I'll keep my eye on them.

As far as the EGR pipe flange - is that off of the exhaust manifold? From looking at the diagrams, I'm guessing that is just above the thermostat? If I remove the air filter box, should that allow me to access?

Thanks!

CATCRD · **Posted:** Thu Mar 10, 2011 9:02 pm

The EGR pipe goes from the exhaust manifold around the back of the engine to the EGR valve. Then another pipe leaves that valve and goes to the intake elbow.

05170765AA and 05142600AA respectively.

SLS · **Posted:** Sat Mar 12, 2011 5:53 pm

When I took my CRD out for a test drive, before I bought it, there was an exhaust leak. It gave us a head ache on a shot drive. Not something you want to keep doing unless you don't like the way you are living. The dealer replaced a coupler and it went away. I think it was between the manifold and the exhaust system. Didn't take them long to find it and fix it!

remwines · **Posted:** Thu Apr 21, 2011 2:38 pm

mvoss15: Did you find the exhaust leak yet? I also have an '05 CRD and too have exhaust gases coming into the cab. Sometimes the fumes are strong, and sometimes really strong. The dealer has taken a couple of cracks at it, changed the elephant hose, but it still comes in. The dealer has given up. I am in California where CRD's were not sold. The deal has worked on only one other CRD, so they have little first hand experience. They have to contact Chrysler's STAR Mechanics just about anytime they work on my Jeep.

I put the Jeep on the lift to look for any sign of suet around the EGR and turbo assemblies, but found no obvious sign of exhaust leaks. From under the hood with engine running, the exhaust odor is strongest around the turbo. My problem may be the same as yours, so I'll be watching to see how yours turns out.

mvoss15 · **Posted:** Thu Apr 21, 2011 2:47 pm

remwines - to be honest, I haven't had much time the last few weeks to spend much more time on this. Unplugging the MAF (Off-Road Mod) seems to have helped significantly. Do you notice less exhaust odor when the MAF is unplugged? I plan to do the GDE eco-tune eventually, so I'm just ignoring the CEL that is lit up for the time being due to the unplugged MAF. Working my hand up to the turbo outlet-area, I do have soot built up around that connection and on the heatshield in that area.

A few Saturdays ago, I was going to try and get at the exhaust downpipe attached to the turbo, but didn't have a long enough socket extension to reach. I'm probably just going to take it to a muffler shop (need a new muffler anyway....the previous owner had removed it) and see if they can pinpoint the leak.

SargeIndustries · **Posted:** Fri Apr 22, 2011 1:36 am

mvoss15 wrote:

remwines - to be honest, I haven't had much time the last few weeks to spend much more time on this. Unplugging the MAF (Off-Road Mod) seems to have helped significantly. Do you notice less exhaust odor when the MAF is unplugged? I plan to do the GDE eco-tune eventually, so I'm just ignoring the CEL that is lit up for the time being due to the unplugged MAF. Working my hand up to the turbo outlet-area, I do have soot built up around that connection and on the heatshield in that area.

A few Saturdays ago, I was going to try and get at the exhaust downpipe attached to the turbo, but didn't have a long enough socket extension to reach. I'm probably just going to take it to a muffler shop (need a new muffler anyway....the previous owner had removed it) and see if they can pinpoint the leak.

Exhaust to turbo clamp is fairly easy to get to if you remove the nuts holding coolant tank to firewall and just move it out of your way. May have to unhook one of the hoses, but should be able to situate the tank so coolant does not spill while you access the clamp from above...

remwines · **Posted:** Sat Apr 23, 2011 10:52 am

I'm installing the GDE Eco Full Torque tune today. It is said that this tune eliminates most of the egr's function, so it may do away with most of the exhaust leak issue. I'll let you know the results.

mvoss15 · **Posted:** Thu Apr 28, 2011 11:46 am

Did you get the Eco Tune installed? Any noticeable impact on the potential exhaust leak?

remwines · **Posted:** Tue Feb 21, 2012 8:05 pm

Hey guys. Been gone for a while and thought I'd better get back into this. The installation of the GDE Eco Full Torque tune did not reduce the exhaust odor problem, but it did correct a lot of the other issues I was having and increased drivability considerably. The exhaust leak has only gotten worse over time. But enough time has passed that I can now see soot around the #1 injector base and will be replacing the seals soon. Thanks for all the input!

dkenny · **Posted:** Wed Feb 22, 2012 12:52 am

if it were up to me to guess..
just an exhaust leak somewhere..

not related to EHM.this might dump crankcase gasses but not too much exhaust..unless something else is wrong.
I added to my wife's jeep 25K miles ago. the first gen dump the CCV into a bottle..I admit I didn't implement this quite correct.cause all sorts of beeps and alarms..at random..even the security system ( the red LED in the lower left of the dash) came on..WE DON'T HAVE THE SECURITY PGK!! all this went away after I remove the 'bottle'..I just dump the results to underside for rust prevention..

-dkenny

New to CRD - exhaust leak issue

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