So 240d has the sound of an exhaust leak it appears to be coming from the rusty down pipe (or header pipe). But i'm not exactly sure, Are these problematic? or should i keep looking before i replace it?

Well, better to isolate the leak before you go replacing something that doesn't need to be replaced. Remember, simply replacing something isn't always as simple as it sounds. Anyway, is possible that your intake/exhaust manifold gasket is bad and leaking. The one in my 240D was shot when I bought it. I just pulled the manifold the other day and the gasket came off in a few pieces. Check out the gasket and see if is leaking aorund there.

__________________
'95 E300D ("Tank") - 231,000 miles
'79 240D ("Biscuit") - 197,250 miles (Sold)
'83 240D ("Ding-Ding") - 217,000 miles (Death by deer)
______________________________________

"Back off, man. I’m a scientist” ~ Peter Venkman

Also check the little pipe that goes from the manifold to the EGR valve. I had a leak this summer that I couldn't find and after pulling the manifold to change the gasket, i took that little pipe off the EGR valve and it was cracked where it takes a slight bend. The bend hides the cracks well. Luckily I had one in decent shape from my scrapped 240 cause those things are EXPENSIVE!

__________________
1982 240D - 251,000 miles (all parts pulled and for sale, body crushed )
1983 240D 4 speed manual - 233,000 miles
2001 Ford Ranger XLT 4WD

I think they have a tendency to rust out the section of pipe just under the battery, just back of the exhaust manifold where it bends down. There is a repair section that you can buy, at least there was 5 years ago when I encountered this.

Rick

__________________
80 300SD (129k mi) 82 240D stick (193k mi)77 240D auto - stick to be (153k mi) 85 380SL (145k mi) 89 BMW 535i 82 Diesel Rabbit Pickup (374k mi) 91 Jetta IDI Diesel (155k mi) 81 VW Rabbit Convertible Diesel 70 Triumph Spitfire Mk III (63kmi)66 Triumph TR4a IRS (90k mi)67 Ford F-100 (??)

I replaced mine a while back, an easy job at a cost of around $15.oo

__________________


1985 Euro 240D 5 spd 140K
1979 240D 5 spd, 40K on engine rebuild
1994 Dodge/Cummins, 5 spd, 121K
1964 Allice Chalmers D15 tractor
2014 Kubota L3800 tractor
1964 VW bug

"Lifes too short to drive a boring car"

I think I have the same problem on mine, I can hear an exhaust leak. Is this a problem that should be taken care of? Or is it just annoying? I've heard bad things about exhaust work, rusted/broken studs, drilling stuck bolts. And shouldn't the EGR just be removed? I thought they weren't good.

__________________
1983 240D 3.0T 4-speed manual, now sold

1989 Subaru GL Wagon 5-speed Touring Edition

It's theoretically possible to get carbon monoxide poisoning from diesel exhaust, but it's unlikely to actually occur since the CO content of diesel exhaust is generally low, and the smell and eye irritation would generally have you looking to end your exposure long before CO poisoning could become a problem.

I drove to San Diego and back several times (wearing earplugs) in my 240D with a cracked exhaust manifold and a flange leak. I mostly drove with the windows open and exhaust in the cabin wasn't much of a problem. I have since replaced that manifold and the car is much quieter.

And EGR is bad, mkay?

__________________
Whoever said there's nothing more expensive than a cheap Mercedes never had a cheap Jaguar.

83 300D Turbo with manual conversion, early W126 vented front rotors and H4 headlights 400,xxx miles
08 Suzuki GSX-R600 M4 Slip-on 22,xxx miles
88 Jaguar XJS V12 94,xxx miles. Work in progress.