Grab a good used one.
Car-part.com has some salvage yards listed in Canada.

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Thanks for the reply. Just looked and there’sa couple near me. Do you think I would just deal with the same problem on a used one? Common issue?

 

Usually exhaust manifolds will tick very loud when leaking. Have a friend hold a rag over the tailpipe and locate the leak, first things first.

P..S. Make the ram Chrysler your winter beater, first things first.

Cheers from Canada, stay safe!

 

Lol I’m not a dodge fan. I bought a Cummins 6 speed manual. Now on topic, don’t notice any ticking, however a few days ago there was a ticking sound and the car ram rough at idle. That was after I disconnected the battery. I figured it had old gas so I went to top of the tank and it’s been running perfect since, just that exhaust smell in the cabin sitting still. I think I should pull it apart to look, then source the parts I need. Wish I had a garage. Wrenching outside in Canada can be harsh.

 

Hello there.....I have an 06 Corolla and the exhaust manifold IS prone to rusting out. I changed mine about a year ago. I also had the exhaust smell in the cabin. My brother in law is a Toyota mechanic and he said it's common.
Too bad I still don't have the picture , it rusts out real bad on the bottom side, not sure it can be repaired. It's quite thin.

I got mine at Rock Auto for less than $275 delivered. I would buy an OEM donut though, as the aftermarket don't seem to last.
They are around $180 CAN at Rock Auto, (click on the Dorman part and add it to cart) plus shipping and tax, it's around $250 sent to my address here in NB. Don't forget to use the 5% discount codes found on the internet.

2006 TOYOTA COROLLA 1.8L L4 Exhaust Manifold | Shop Now at RockAuto

Exhaust & Emission Parts and More for Your 2006 TOYOTA COROLLA at Reliably Low Prices. Fast Online Catalog. DIY-Easy. Your Choice of Quality. Full Manufacturer Warranty.

www.rockauto.com

That isn't a "do it outside" job, especially if the car is a daily driver. If you brake a manifold stud, you're in trouble. It can turn into a fairly tough job if things go bad. If the bolts come out ok, it's fairly easy.

PS.....it may be your converter pipe bad also. Those are expensive, check with the dealer. I got mine on Amazon.ca for cheap. Works fine..

AB Catalytic 51274.5 Catalytic Converter, Catalytic Converter - Amazon Canada

AB Catalytic 51274.5 Catalytic Converter in Catalytic Converter.

www.amazon.ca

Good luck....

 

I would replace the doughnut gasket from the end of the exhaust manifold to the midpipe.

Depending on which has station you use can emit the smell too.

 

I crawled under the car while it was on ramps in my driveway. The converter and piping was rusty, but I didn’t see or hear any holes. When I was under the hood feeling in behind where the exhaust manifold meets the pipe at the doughnut gasket, I could smell strong exhaust. I’m pretty sure it’s the manifold. I still have my truck insured so I can drive that too and from work for now. The oem exhaust manifold is $285 from Toyota parts direct Canada. I’d go that route over the dorman

 

Tomorrow I’ll pull the heat shield off I can get to it from the top of the motor and I’ll have my wife plug the exhaust partially and I’ll see if I can find out where the leak is coming from. Thx guys.

 

Good news. I took off the shield looked for cracks in manifold. Didn’t see any and fairly rust free. I took my shop vac and put it on blow and pressurized the exhaust system. Then I sprayed soapy water all over the manifold and near the donut gasket massing surface. The leak is at the donut gasket. Yes!!

 

yeah its a common failure point, the gaskets just wear out over time as the pipe flexes back and forth over the gasket. Might want to replace the rear flange gasket as well while you're down there, entirely up to you. I've heard good things about the QRP replacement gaskets. Some people have claimed fel-pro is good others not so much. If you want to do it once and never worry about it, pay extra for an OEM gasket. If the bolts and springs are rusty replace those too. It's about $140 in parts if you get all OEM gaskets and springs and bolts for front and rear flange, significantly cheaper if you go aftermarket.

 

Great news. Hopefully the manifold studs dont break when you try to replace the donut. Then the manifold has to come out. Good luck

 

I guess I underestimated this job. I was thinking I could just buy a new donut gasket and separate the manifold from the catalytic pipe with the 2 spring bolts. Is there not enough flex in the exhaust to move it back a couple of inches and replace the donut? At first I was thinking of taking the car to a muffler shop, but then I thought this should be easy and I could tackle it.
I now have a check engine light. I disconnected the 02 sensor at the clip to remove the heat shield. Started the car when I had it reconnected and I have the light. I can’t remember the code. My alphaobdmx plus is all I have to look at and clear the codes.

 

You shouldn't have to remove anything other than the 2 spring bolts at the flange and slide it apart....

 

Right, "from underneath".

 

That’s what I thought. So my code is P0031. Directly related to the front 02 sensor. When I’m on days off I’ll unplug the sensor again and put some dialectic grease on the connection. Car runs perfect right now. Thanks guys. I think I’ll try to fix this myself. I sprayed some penetrating fluid on those spring bolts but I’m sure it’s burnt right off by now.

 

you probably didn't fully clip it on and it fell off.

 

Disconnect the battery and the light returns? Check the wiring to the o2 sensor to see if it's been rubbing on something

 

More good news. I got the car fixed today. Picked up a new oem donut from my local dealer and went to work. Used my electric impact to get the old spring bolts out, and they came out easy. Old donut was in pretty good shape. Installed new donut and gently used my electric impact very slowly with inward pressure to seat the bolts into the manifold nuts. Checked for cross threading, and i was good to go. Went back and forth and torqued to 40ftlbs. My big torque wrench wouldn't go lower, so that's what i used. No leaks and no smell so far. Looked into my 02 sensor code and issue. When i clipped the 02 sensor back in i must not have applied enough force. It came undone and was laying near the manifold. Plugged that back in, reset the code, and good to go. Going to try to program a couple of new keys today and then this car is ready. Runs great with 99k miles on it. It's a USA car and I'm in Canada. Has a couple of dents that i'll try to deal with in the spring. Thanks for the help guys. I'll ask for help in the future, and i'm here to offer help to those who ask. Take care

Mike

 

An update, so my exhaust manifold is cracked. I still had exhaust getting into the cabin of the car. I found the leak right off one of the header tubes on the bottom side, second cylinder from the passenger side when facing the front of the car. Pressurized the exhaust, and found the leak with soapy water and using my hand. A lot of air was leaking. I also still have a leak at the donut gasket. I'm done with messing with it so i bought a new oem manifold from toyota parts direct for $283, and a new header gasket. I'm having my local toyota dealer install the manifold. They quoted 1.1 hours. I don't have the tools to make the job easy. The car is also getting an airbag recall done. Wish me luck at the dealer.

 

Cat Con rusts out also and gives the exhaust smell. Just had mine replaced on my 2007. The shop said they have done many of them.

 

Got the corolla exhaust manifold swapped at my local dealer today. Did it in the 1.1 hours stated in the shop manual for job hours. Paid $177 out the door with my air bag recall done also. I noticed that they either lost or broke one of my valve cover (plastic) nuts or stud. There is a new bolt on one side securing the cover. It's not the acorn style, it's a bolt. I've had them off numerous times over the past few weeks. I think they lost one. I did have a tiny oil leak on that stud where the acorn nut attaches. Maybe they swapped to the bolt to stop this, not sure. Anyways, no exhaust in the cab any more. I'm happy and my kids will be too.

 

In my case, the donut gasket actually wore through the female part of the exhaust flange attached to the catalytic converter....manifold was fine. Given that the flange is unusually large for this generation of Corolla, I haven't had any luck finding one new and am resorting to seeking out cars that are being parted out to find it.

 

you'd probably be best off taking it to an exhaust specialty shop (one of those places that ONLY does custom exhausts and nothing else) they can likely get the correct part and weld it /install it for you for fairly cheap.

 

I still have slight exhaust smell in my car when the heater is on and I’m stationary. Manifold is new, donut is New, manifold gasket is new, and all oem. I wonder if I have this same problem?

 

are you even sure it's exhaust you are smelling? it could be an oil leak and you're smelling oil burning off the block or the manifold

 

I’ll look further but there is no oil residue that I’ve seen on the motor so far. I’ve only owned the car for 6 weeks. I’ll look into it. Fairly sure it’s exhaust, but fairly minor compared to when my manifold was cracked.

 

If you still have the black leaking intake manifold gasket, replace it with revised orange silicone gasket #17171-22060. I could smell crankcase fumes similar to exhaust emissions before I had replaced mine.

DIY 2003-2008 Corolla, Matrix, Pontiac Vibe Intake Gasket replacement with PICS!!!! | Toyota Nation Forum

 

I looked a couple of weeks back and saw an orange gasket tab sticking out at the intake. I’m taking the car to my local Toyota dealer who installed the manifold so they can confirm and diagnose my problem. It’s definitely exhaust. I idle the car this morning while I loaded up the car with my work gear to come home. Car was pretty full of fumes. I’d like to know what to carbon monoxide levels are in the car when I’m stationary. This problem has been challenging to fix. I’ll get there eventually. Hopefully it doesn’t cost too much.

 

Maybe you have a drain plug missing underneath the floor and more exhaust leak from somewhere. Chance it could be underneath the center console leaking in or somewhere by the firewall.

Do you have any road noise inside the cabin?

Does your car get moisture inside after rain?


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I’m not sure. It is a fairly noisy car to drive and the exhaust isn’t silent, it’s kind of raspy, but no loud. Road noise is better than my wife’s civic. I’ll update tomorrow after I pay the dealer and get the diagnosis. Thx for the help guys

 

stock corolla's are pretty quiet cars... probably have a hole somewhere in your exhaust.