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VW B5 Passat TDIs This is a general discussion about B5 Passat(>98 (2004-2005 in North America)). Non TDI related postings will be moved or removed.

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Old August 18th, 2019, 06:37   #1
Jake Brake
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Default Hard to find exhaust leak

I am pretty certain i have an exhaust leak because no puff of black smoke. I have a pretty loud hiss when building boost.
What i have done
1: bypassed egr cooler
2: replaced flexible exhaust piece by cat.
3: cleaned and looked all over for soot tracks
It only leaks under moderate to high boost and does zap some power.
Working on making a homade smoker system with an old soldering iron, paint can and acouple of fittings and baby oil with an old sock for a wick.
My question is how prone to cracks are the exhaust manifolds?
How prone to blowing out exhaust manifold
gaskets?
How big of a pain is the manifold to remove?
Found out if egr and cooler is off you can remove down pipe with cat out of the top. It has to be jacked up pretty high to do so.

Last edited by Jake Brake; August 19th, 2019 at 17:14.
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Old August 21st, 2019, 09:32   #2
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Are you sure it isn't a boost leak in the intake system?
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Old August 21st, 2019, 09:34   #3
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Never seen an exhaust leak on any BHW car ever.

Seen plenty of charge air leaks, though.
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Old August 21st, 2019, 13:45   #4
Jake Brake
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It might be, no smoke though. I have taken off the front bumper cover and checked each connection of my front mount intercooler too. My flex piece on the exhaust was definitely bad.

I will finish my smoker and try it on the intercooler side. Got 2 young grandkids to look after, daughter had major back surgery and not a lot of time to tinker right now.

Last edited by Jake Brake; August 21st, 2019 at 13:49.
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Old August 21st, 2019, 13:54   #5
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Have a beaded lip on all my intercooler pipes and T clamps. I cleaned all connections and used hair spray to make the pipes stay put better.
Hair spray works pretty good on a grease free pipe and coupler hose. I sanded the polished area of the aluminum pipes that are clamped as well.

Last edited by Jake Brake; August 22nd, 2019 at 13:09.
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Old August 22nd, 2019, 18:53   #6
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Quote:
Originally Posted by oilhammer View Post
Never seen an exhaust leak on any BHW car ever.
Seen plenty of charge air leaks, though.
Come to Canada We live in the "salt" belt, just about every BHW needs a mid-muffler here!
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Old August 23rd, 2019, 03:44   #7
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I bet. I see some stuff periodically from the salt belt. It is awful, no idea how you guys deal with that.
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Old August 23rd, 2019, 07:39   #8
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He meant eastern Canada.
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Old August 23rd, 2019, 09:37   #9
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Thanks guys, I'll post back when i find my leak.
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Old August 23rd, 2019, 09:50   #10
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Quote:
Originally Posted by oilhammer View Post
I bet. I see some stuff periodically from the salt belt. It is awful, no idea how you guys deal with that.
It's simple, we have to buy cars more often. The VWs have excellent corrosion protection and last a long time. Mazdas on the other hand, if you are quiet, you can hear them rust!
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Old August 23rd, 2019, 19:51   #11
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In fact my BHW had a new mid muffler just before I took it off the road (car was rotten) if anyone needs one!
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Old August 29th, 2019, 17:52   #12
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I finished my smoker and tapped into the intercooler side. It was coming from the intercooler. The smoker works brilliantly! Used a friends old nebulizer pump to push the smoke.
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Old August 30th, 2019, 03:23   #13
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Do NOT try an eBay intercooler. Just get an OEM (Modine) one. Trust me on that.
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Old August 30th, 2019, 17:09   #14
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I was already running a front mount intercooler. I have pitched many of the original hoses.
The intercooler is a bar and link type.

Looked around my garage and found most of what I need to hook up the stock intercooler.
May go ahead and hook it back up. I have get a new hose for the one off the turbo.

Last edited by Jake Brake; September 1st, 2019 at 07:34.
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Old September 3rd, 2019, 06:21   #15
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That's the expensive hose.
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