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Exhaust leak firewall bank.

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Old 04-02-2011, 05:53 PM
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Exhaust leak firewall bank.

It happened all of a sudden after I got into the car, started it and put it in drive. It appears that there is a leak in my exhaust somewhere between the motor and the firewall. I looked up in there and can't find anything out of the ordinary.

Anyone with any insight, can you please chime in.

My car is up on jackstands and I am tearing it apart. WIll check back in a bit.
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Old 04-02-2011, 06:07 PM
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After researching, I am coming to the conclusion that I broke a manifold bolt. Has anyone changed out their own mani studs? Doesn't sound like fun.
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Old 04-02-2011, 06:20 PM
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Drilling out a broken stud is never fun . You may be able to get a angle drill in there to get it out. You may get lucky if you pull the manifold there may be enough to grab with vise grips. PB blast the **** out of it before you try to remove it . The best way IMO is to pull the head.
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Old 04-02-2011, 08:10 PM
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I'm gonna have to agree that pulling the head is the best way. Thanks for the advice, hopefully i won't have to go this route.

Ok, just got back in from tearing apart the car. All the bolts and studs on the rear bank look fine. Nothing looks broken or loose. I did notice when removing the Stock y pipe that the rear upper O2 sensor was a little loose. About 1/2 turn.

My question: Do you think that a loose O2 sensor can make that much noise, like your exhaust got disconnected?

Whatever the case is, I putting the car back together in the morning after I get the bolt that broke out of the exhaust and pick up some new bolts.

Another question: Are exhaust bolts hardened?
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Old 04-02-2011, 08:21 PM
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I'm not sure ... But if it was 1/2 turn loose I would think it may leak enough to produce the sound your describing .

Don't know if they are hardned but they are alot better quality then the ones they used on my 84 turbo z. at least half of them break no matter what you do to try to prevent it. Total PITA!!!
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Old 04-02-2011, 08:36 PM
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zcar84, thanks for the reply. I'll get back to this thread tomorrow after the car is back together. Also, another thing I noticed is that there is a washer stuck between the head and the exhaust manifold. I'll take a pic and post it tomorrow. It's smashed in there and there has never been any work done to the motor. The washer is not near a bolt or stud and it's just pinched in between the head and manifold. Kinda funny.
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Old 04-02-2011, 08:39 PM
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Sure man no problem ! Just make sure to post a picture of this washer.
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Old 04-02-2011, 10:38 PM
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Pulling the head is unnecessary!!!!! If you do have a broken stud the removing the Xmember, ypipe and rear exhaust should provide you plenty of room if you have a snake drill (aviaton flexible drill shaft)....maybe with the exhaust manifold removed there will be enough stud left too remove with a small set of Visegrips...GL
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Old 04-02-2011, 10:39 PM
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Originally Posted by Edward Lee
zcar84, thanks for the reply. I'll get back to this thread tomorrow after the car is back together. Also, another thing I noticed is that there is a washer stuck between the head and the exhaust manifold. I'll take a pic and post it tomorrow. It's smashed in there and there has never been any work done to the motor. The washer is not near a bolt or stud and it's just pinched in between the head and manifold. Kinda funny.
That's the Gasket dude!
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Old 04-02-2011, 10:43 PM
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Worn engine mounts and damaged exhaust seal gasket @ Ypipe ehaust manifold flange...break out a hose and listen for the leak b4 taking apart alot of crap!!!!
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Old 04-03-2011, 08:13 AM
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Originally Posted by CMax03
That's the Gasket dude!
Haha, I sure hope it is. It doesn't looks like a part of the gasket but you never know. I'll snap a pic of it when I crawl back under there.

Originally Posted by CMax03
Worn engine mounts and damaged exhaust seal gasket @ Ypipe ehaust manifold flange...break out a hose and listen for the leak b4 taking apart alot of crap!!!!
Cmax, car already apart, snapped an exhaust bolt in the process. Anyways, the motor mounts on the car are all brand new, about 1 year old. The metal gasket where the Y meets the exhaust manifold looks perfect as it was replaced when the car went back to stock from an aftermarket Y-pipe that I didn't like (too loud).

I actually think that it's that loose O2 sensor that was causing the noise. Please feel free to chime in again if you can think of anything else it can be as I am on my way to get some tools to get the 1/2 bolt out of the Y-pipe and then reassemble the car.

Thanks for all the input. :-)

Last edited by Edward Lee; 04-03-2011 at 08:20 AM.
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Old 04-03-2011, 11:30 AM
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Break out that cheap a$$ stethscope and listen for that exhaust leak! Did the stud break even with the manifold? I hope it did for you sake! Did you snap it tighten it or loosening it? Did you reuse the Exhaust seals? They may look good but they're crushed and not reuseable.....
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Old 04-03-2011, 03:20 PM
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I didn't snap a manifold bolt. I snapped an exhaust bolt and it's already fixed.

All the manifold bolts are fine. The leak is not from the exhaust manifold nor was it from the y-pipe gaskets as they were sealed tight. I was explaining to you why all your theories checked out negative. You didn't get it.

Your stethoscope advice isn't going to help either as I posted that the car was already apart. It's going back together now. Should be done in 15 minutes.
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Old 04-03-2011, 10:08 PM
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Sorry didn't read all of your post, my bad! But maybe next time you oughta look a little better b4 you post a thread about nonexisting ****...... Or start removing components without thorough troubleshooting your problem and I wouldn't have too say anything too you...Dude!!!
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Old 04-04-2011, 03:54 PM
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Got it! Blown EGR valve. Just spent the better part of an hour removing it. Not too hard and took pics along the way.

Anyways, here is that pic of the washer in between the manifold and head.




Last edited by Edward Lee; 04-04-2011 at 08:57 PM.
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Old 04-04-2011, 08:59 PM
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And here's a pic of the blown EGR valve (upside down). Notice that the bottom of the valve is completely gone.

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Old 04-04-2011, 09:10 PM
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Wow that washer looks strange... Definitely looks out of place.

I have never seen a EGR valve blow it's top like that . Good you finally got to the bottom of your problem .
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Old 04-04-2011, 11:20 PM
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Yea, both strange occurrences. Funny thing about the EGR is that nothing was clogged up and there was absolutely no buildup in any of the tubes attached to the EGR.

The washer baffles me and it sure doesn't look like a part of the gasket. The car has never been taken apart so who knows if it's normal or something happened during the manufacturing of the engine.
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Old 04-04-2011, 11:31 PM
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Man I would save that EGR ! It would be a interesting conversation piece.
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Old 04-05-2011, 02:49 PM
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It's a 4 bolt pattern and you only use two of them @ each port!!!!!!!!
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Old 04-05-2011, 02:55 PM
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Here's my exhaust gasket pic!!!!!! What I don't understand is if you had all that off why you didn't see that!!!!

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Old 04-05-2011, 07:38 PM
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Originally Posted by CMax03
It's a 4 bolt pattern and you only use two of them @ each port!!!!!!!!
Why isn't there one to the right (next exhaust port) of that gasket bolt hole in my pic?

Also, I never removed my exhaust manifold.
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Old 04-06-2011, 05:51 PM
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Originally Posted by Edward Lee
Why isn't there one to the right (next exhaust port) of that gasket bolt hole in my pic?

Also, I never removed my exhaust manifold.
Because they criss-cross the stud arrangement at each port, look diagonally from the one on the lower right side of the center exhaust port and there's one on the upper left side of that same center port!!!!! You're only using 2 studs at each port so they'll be hanging out if they're not covered by the manifold! nothing to worry about......
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Old 04-06-2011, 10:49 PM
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I looked at all the ports and that's the only one where that washer or gasket shows.

Anyways, got the car back together. Total tome to change an EGR valve, coming in from the top took me about 1 hour.
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Old 04-07-2011, 06:39 AM
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Glad to have it back together?
I am finishing my max's clutch tomorrow afternoon!
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Old 04-07-2011, 10:59 AM
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Awesome^^^.

I can't believe that only 2 members chimed in on my thread. I've been a donating Maxima.org member for 9 years and am a little surprised to see that there is no help to be offered, by more members. Granted, I haven't been on this site for a while since I'm over at the Audi forums, but still.

However, thanks to the 2 members who did chime in and offer their opinions.
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Old 04-07-2011, 11:38 AM
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I am glad your happy again a broke maxima is no fun .
That seems to be the norm. Here . I commented on a replica lip group buy and got a smart a$$ response . That I should have searched. Thought the purpose of a car forum is to share thoughts ideas and to help others?
I will give any input if I feel I can help.
Just like the thread I started about having a steel flywheel made . All I seemed to be getting were negative comments. When all I was trying to do was offer my experience because I didn't see anyone using one.

Last edited by datsunzcar84; 04-07-2011 at 11:42 AM.
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Old 04-07-2011, 08:42 PM
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Originally Posted by Edward Lee
I looked at all the ports and that's the only one where that washer or gasket shows.

Anyways, got the car back together. Total tome to change an EGR valve, coming in from the top took me about 1 hour.
I looked @ my Cattman header installed and I saw the 2 outer ports with 2 gasket bores showing each....If you're curious E.L. remove it!!!!!!
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Old 04-07-2011, 10:22 PM
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Not gonna happen. I am over this car and would really like to sell it and move on.
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Old 04-09-2011, 02:04 PM
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Originally Posted by Edward Lee
Not gonna happen. I am over this car and would really like to sell it and move on.
Wow unbelieveable!!!!!!!!
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Old 04-09-2011, 04:48 PM
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I think I'll put my garaged car into daily duty and put another toy into the garage. Got my eye on a GT3.
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Old 04-09-2011, 08:29 PM
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Originally Posted by Edward Lee
I think I'll put my garaged car into daily duty and put another toy into the garage. Got my eye on a GT3.
If you can afford a GT3 your the man!!!!!!!
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Old 04-10-2011, 12:15 AM
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It's a used 2008 997 from a friend who wants to sell it. 7k miles and a garage queen that he never drives. The price is too good to pass up. I want it but am torn on taking the current queen out of the garage and parking it in the driveway. I've been putting off the purchase but since the maxima is starting to give me troubles, I'm am getting tired of it. In the last month, I have replaced: alternator, water pump, front wheel bearings and now the EGR valve. Here is the current GQ.

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Old 04-10-2011, 07:19 AM
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That Audi is bad @$$ !!!
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Old 04-10-2011, 08:34 AM
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Wow nice! So if this gives you even trouble you'll be getting rid of it really quick as well? It's called maintenance and all cars need it sooner or later....just think about it....did you have too pull the engine due too an inferior bottom end or topend? But anyway if the Maxima is hitting that wallet hard, imagine how hard a GT3 or A4 RS is gonna get you when it's time for minor maintenance! German vehicle are outlandishly expensive in a maintenance perspective in dealing with dealership/Repair shop rates and those overly expensive parts! Back in the day when the saying was..."Foriegn cars are very expensive to maintain" ...that jerk wasn't talking about those Japanese vehicles!
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Old 04-10-2011, 09:41 AM
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First of all thanks for the compliment on the car. This isn't my first german car. I also have a 2008 GTI and had an S4 prior to the Rs4. I just replaced the brakes on the RS4, and at almost $400 per rotor and $350 for the front pads, I can agree that it's not cheap. The mods to the RS are Milltek Catback, Ohlin suspension, HRE Monoblock wheels, H&R sways, Euro Flat bottom steering wheel, etc...

There come a point of diminishing returns where the money going into the car exceeds that cars value, that's when it's time to let someone else deal with it. Maybe it's just an excuse to get another toy. Whatever the case is, I realize that German cars are expensive and have come to accept it. The payoff in driving pleasure is worth it to me.

Enjoy the pics.



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Old 08-13-2011, 07:59 PM
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This thread has alot of good info, but I still cant seem to find any egr tubes on my 01 ..

I found alot of helpfull links for 95-99 , but I cant find one for my 01.

I found one part of the egr under the throttle body, but I dont see any tubes or anything going to it just a vacum line.

As I aswell am trying to hunt down a exhaust leak...

help me out guys.
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