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I've got the same problem. I think I've tracked it down to a leak at one of the slip joints. From there the exhaust fumes must flow into the engine compartment and get sucked into the HVAC system. If I don't turn the blower on and keep the windows up, I don't get any smell inside the car. But, as soon as I turn the defroster on the fumes are almost instantaneously inside the cabin.
I'm getting the leak fixed next week and we'll see if that cures it.
Let me know for sure. I did notice that the 2 slip joints going directly into the header had some extra room during the install, but the clamps seemed to take care of it. How do you plan on fixing it? I dont want any welding or crimping done to the piping.
Let me know for sure. I did notice that the 2 slip joints going directly into the header had some extra room during the install, but the clamps seemed to take care of it. How do you plan on fixing it? I dont want any welding or crimping done to the piping.
My most obvious leak is coming from the slip joint in front of the cat. I'm going to pull it apart and probably need to cut a couple slits in the cat to allow the band clamps to compress it a bit farther. That should fix the leak and hopefully also the HVAC interior smell.
I'll keep you posted as to what I find after getting it apart and how well my fix goes.