CS downpipe fumes

[sawdust777]

2010 Speed3 CBE, DP, RJI, APT

After installing the CSDP, I am having exhaust fumes leak into the interior of the car. Ive checked all the joints and cant find any leaks. At least I cant hear, feel or see any. I have no idea where they might be coming from. With the AC on recycle the interior air I have no issues, but with defrost of vent on it gets bad really fast.

Anyone else have this issue ? Advice ?

[jdmage_mx5]

I'm pretty sure that means there is an exhaust leak. Also if you deleted one or more of the cats that does not help the situation. Did you use a new gasket for the Downpipe to turbo?

[roguemazda]

put some washing up liquid round the joints of the down pipe, it will start to bubble where the exhaust gas are escaping from

[roguemazda]

forgot to say car needs to be running when doing this

[sawdust777]

Originally Posted by jdmage_mx5 I'm pretty sure that means there is an exhaust leak. Also if you deleted one or more of the cats that does not help the situation. Did you use a new gasket for the Downpipe to turbo?

JD - Yes front Cat removed. went with catless DP

[MSP6]

Dude....use your brain. You replaced an exhaust piece and now you get bad fumes in the cabin immediately........its leaking....undo the connections and check your gaskets then reconnect.

[sawdust777]

Yeah , MSP6 I kinda knew it was leaking but there wasn't an obvious leak when I checked it in poor lighting setting. I will be sure to use my brain when I get it in my garage. And I'm pretty sure that I knew to check all of the connections too. You should be a mechanic / comedian full time. I was simply asking for the best place to start in case anyone had the same issue.

[MSP6]

I only meant to be half an asshole....

Leaks can be seriously bad without being visibly noticeable at all, even with the best of lighting. My downpipe had damn near backed itself off my turbo and the only reason I noticed was my AFR's went whacky.
I was pointing out that you hadn't done 30 things at one time. You removed and replaced 1 item, and now have an exhaust leak. Where do you think your culprit is?


Also....if you're to survive here you'll need thicker skin. That was a friendly tap on the noggin to try and make you stop, slow down and think.

[kidlifecrisis]

Also check to be sure you put the spring bolts in correctly and didn't bottom them out, the springs need a little gap to do their jobs.

Which cs dp is this? I have the one piece long dp (which I believe is discontinued) with 80mm outlet, I had some leakage when I still had the stock catback. Check the dp to midpipe and make sure the sizes match

[F4LL3N]

Are you pulling any codes? Usually turbo to downpipe you'd have around 20% Long Term FT and pulling lean bank 1 codes. I ran straight out the downpipe at one point and my AFRs were fine. Smelled like shit, but racecar.

[skoski17]

I did the same thing but deleted the cats and since doing this, I do smell fumes from time to time. I figured it was because of the delete.

[JgamB]

Unburnt hydrocarbons stink. If you're sitting still or in a garage, you're going to smell it if you're catless.

[sawdust777]

Update: pulling no codes, small leak found bottom rear corner of turbo / downpipe gasket. and yes its the hardest one to get to. Going to replace the gasket and try again. For those who might at some point need to replace this gasket and find the $96 dealership price or even the $49 SU price a bit much, check out the Remflex RF18-020 for $22. It doesn't specifically list the car models but it looks exactly the same. I will know more tomorrow.

[kidlifecrisis]

Originally Posted by sawdust777 Update: pulling no codes, small leak found bottom rear corner of turbo / downpipe gasket. and yes its the hardest one to get to. Going to replace the gasket and try again. For those who might at some point need to replace this gasket and find the $96 dealership price or even the $49 SU price a bit much, check out the Remflex RF18-020 for $22. It doesn't specifically list the car models but it looks exactly the same. I will know more tomorrow.

I happen to be looking for that gasket as well and was shocked at the price, let us know if the one you found works

[kornybun]

Remflex gaskets are the shit. I used one to seal up my Ebay dp to mid pipe. They are great for sealing uneven gaps. Didn't know they made one for the K04.

[sawdust777]

The Remflex is the answer ! fits perfectly and seals easy with less torque. Tell the world.

And that fixed the leak at the downpipe / turbo.....but I found another leak that no gasket can fix. I am thinkimg that this new issue should be a new thread but essentially, the friggin CSDP was broken at a tig weld. I had to remove the whole pipe and have it mig welded. I have had great success with every product from Corksport up until now and I wont smear their name, but the tig weld on this particular pipe was kindy crappy.

Anyone know if the stock motor mounts are to blame for stressing the DP ?

Either way I'm up and running with NO LEAKS !

[LatinKraze]

I bought a used CS DP, it was cracked at the welds to the flange. Got it rewelded before install and it's been fine for 2.5 years but I'm fully mounted.

[ASHMS3]

Did you buy new or used? Motor mounts or not it shouldn't cracked that quickly if new. It's good you got it figured out though, and thanks for the info on the gasket.

[sawdust777]

Originally Posted by ASHMS3 Did you buy new or used? Motor mounts or not it shouldn't cracked that quickly if new. It's good you got it figured out though, and thanks for the info on the gasket.

No, I bought the pipe new and have had it on the car a while. No idea when the weld snapped but Im guessing probably around the same time I started smelling fumes, but then again the gasket was also fried. I ordered the CS motor mount inserts to head off any future stress to that pipe.

[Turbo_Steve]

Originally Posted by sawdust777 Update: pulling no codes, small leak found bottom rear corner of turbo / downpipe gasket. and yes its the hardest one to get to. Going to replace the gasket and try again. For those who might at some point need to replace this gasket and find the $96 dealership price or even the $49 SU price a bit much, check out the Remflex RF18-020 for $22. It doesn't specifically list the car models but it looks exactly the same. I will know more tomorrow.

Yes, that remflex piece is for our k04. I was working with them to have one made and they already has it in their catalog. They have drawings of our turbine flange and manifold flange also but didn't do anything with it yet.

Also should add that for exhaust leaks I built a tester similar to a boost leak tester that I slip over my exhaust tip. You can check for leaks on a cold car and won't burn your hands.

[F4LL3N]

If you're doing the gasket, just slab the shit out of it with RTV and put it back on. $9 fix. My downpipe gasket has been through all sorts of shit, and it still holds.

[SpencerC]

Glad you figured it out. I'm curious how long you have had the downpipe though.

[sawdust777]

Originally Posted by Spencer@CorkSport Glad you figured it out. I'm curious how long you have had the downpipe though.

Spencer- had it on the car for about 1.5 yrs

[SpencerC]

Hopefully you submitted a warranty form here: https://app.smartsheet.com/b/form?EQ...dfd91666d9c770

[sawdust777]

Originally Posted by Spencer@CorkSport Hopefully you submitted a warranty form here: https://app.smartsheet.com/b/form?EQ...dfd91666d9c770

Spencer,
I appreciate the link and I just sent the form in documenting my issues. I do not have much documentation of the original purchase date or install date ( there was a significant delay in installation). Not sure what can be done at this point and I am not overly concerned with it either. I just was surprised that your product was not perfect as they usually are. Worry not, I am a loyal customer of Corksport and I am not going anywhere anytime soon.

[sawdust777]

Spencer,
CS has made everything right by me. I didnt intend to ask for, or really expect any gesture on their part but they went above and beyond. You guys have some of the best customer service I have ever seen ! BTW give Kelly at ext 103 a huge raise. She was fantastic !

[Frequentflyer]

I have this same issue CSDP. I keep the A/C fan on recirc. I haven't had the time nor the patience to get in there and find out where it is coming from. I don't think mine is cracked though.