Exhaust leak

[Grabber12]

I've been chasing down what seems to be an exhaust leak. The leak sounds to be on the passenger side header/manifold. In the mornings it's kinda loud then goes away once it's warmed up. I had a shop look at it but they could not find a leak. Is it common for our manifold gasket to leak? How difficult is it to replace?

 

[SoHK_alumni]

Cracked exhaust manifolds, particularly with the earlier tubular style are very common.

 

[Turdle]

Yes.
If the manifold was taken off it would do this

IMO the best bet is to replace it with the later style cast manifold, plug the egr port if not needed.

 

[Grabber12]

It seems like it's only the passenger side so could I just do the one side with the manifold style and leave the other side alone? Also I live in CA and must smog so the EGR port will be reused. Are you guys accessing the bolts through the fender well?

 

[Grabber12]

I'm thinking about going to the junk yard and finding a 99-2000 so I can get the cast iron style. Any advice on pulling the passenger side? Some wd40 and a breaker bar.

 

[SoHK_alumni]

Yes, in through the fender well for most bolts.

Inner right downpipe bolt is a royal pain.

Use a real penetrating oil rather than WD40.

Be prepared to fight the external EGR tube.

New, the cast manifolds are well under $100.