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Exhaust Leak Saga, Continued...


burnout8488

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I recently did a little overhaul of my car, resealing both the cam cover and oil pan, new OE exhaust manifold gaskets, and a blasted Japanifold with all new hardware. This was in hopes that my exhaust leak would finally go away.

Upon reassembling everything, the sound of the leak didn't change AT ALL. Having all of the exhaust components removed, you would think putting it all back together might yield a change.

It's a metallic sound, and I can hear the whistle of the turbine on deceleration through it, loudly. At idle, the leak sound goes away completely and the engine idles quietly. When at full throttle, the smell of exhaust enters the cabin and stinks.

I've felt around with the engine running and can't feel a thing. Is it possible the band clamp around the CHRA and (brand new) exhaust housing is leaking? It is super tight, is there a method of seating it by tapping it down with a hammer or something?

The car has had two different downpipes, and two different manifolds since switching to my 15G, and this leak has remained. Is the CHRA to exhaust housing connection a feasible leak point? Anyone ever heard of this before? Maybe the little disc that sandwiches between the turbo and exhaust housing needs to be sanded down shiny?

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