Discovery and final repair don’t always go “hand-in-hand”. After welding and reinstallation, I again tested for leaks. Whoa, looky there another leak, actually leaks. First one: Exhaust manifold stud sheared off in cylinder head. Looked as if it was still securing the manifold with a nut and washer, but smoke pushed by behind the washer. Warped manifold is normally the cause. Right then I remembered the freshly replaced catalytic convertor. Removed head pipe and heat-shielding again, pushed oil based smoke into it and more welds showed where they were cracked too. Here’s another photo;
Normally as the convertor starts to plug up it causes exhaust system in front of it to super heat, which in turn can make for cracks and breaks if driven for a while.
One and a half hours later all welds were ground out and replaced. Smoke testing the system after installation showed that part was now sound. BTW a replacement part costs around $500.00. The car was originally here for brakes, not exhaust leaks.
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