Strange exhaust leak with pic - Toyota Nation Forum : Toyota Car and Truck Forums

Krmnnghia · 06-18-2010, 08:10 AM

Ideas?

How is there that big of a sleeve in there and why would it break off almost perfectly around the entire pipe? Cheap aftermarket downpipe maybe but why would it break where it broke? Car is super sluggish and loud under the hood and outside due to the massive exhaust leak. Just bought the car(93 2.2) with 198K on it so just did a full tune up and found this nastiness.

73sport · 06-18-2010, 09:54 AM

Great closeup which results in an answer. . .

Look close, its only spot welded in a couple of places and relied on the inner sleeve to seal it. Not a 360 degree weld as it should have been.

In short, poor workmanship put it where it is. Broken.

Now that gap bewteen the manifold and the flange can't be good either. It looks like the weld distorted the pipe flange and even if you fix one, the other will be an issue.

Are the motor mounts OK? (Suggest power brake with hood up to observe engine movement.)
Is there a flex pipe under the car?

73sport · 06-18-2010, 09:59 AM

Oppsee - - what i didn't say was that it looks like the pipe was either cut apart or replaced and then tack welded back together.

Krmnnghia · 06-18-2010, 10:04 AM

The motor mounts seem to be in good order although I have not done the hood up test. Dogbone could be replaced as it has a crack in the rubber but from what I hear this has little to do with rough idles which this car does not have. So it looks like a PO did some cheap fix on it and the best thing to do would be just replace that entire downpipe which includes the flex piece? Yes it does have the flex pipe and it looks to be in good order.

73sport · 06-18-2010, 10:21 AM

Someone could feasibly weld it back together. Cost would be minimal if it aligns OK. Not sure about getting enough access to do it though.

That still leave the flange issue.

And yes, that is you only next option => repalce it.

Krmnnghia · 06-18-2010, 10:32 AM

Looks like replacing it is the way to go then...welding it so it can just fail again after being heated up and cooled down 100 times doesn't seem smart. I think Napa quoted me like $140 for that piece. ugh Thanks for the help!