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JOJO126,
I did not notice that you confirmed the smell is exhaust or vaporized Diesel fuel before it is burned. In either case, the way they typically enter the cabin is through the ventilation system. The air intakes are at the base of the windshield, and the hood is not sealed to the fenders when shut, so anything in the engine compartment is free to exit through the gaps in the hood and get sucked into the ventilation system. This would suggest your odor is coming from the engine compartment and not underneath the car. If it is exhaust, I would expect a little elevated noise level. I just had the intake and exhaust manifold gaskets replaced on the family 240D. The engine mounts failed and the engine bounced around so much starting the car that the exhaust manifold studs got stretched/strained and the car developed an exhaust leak. It was pretty loud, and it did enter the cabin area, but it was not severe enough to make clothes smell or give you a headache.
On other occasions I have had the daisy chained injector bypass lines fail, especially the plug on the last cylinder's injector, and had pretty serious stench of Diesel fuel, not exhaust, enter the car. When they leak and the car is running the fuel evaporates when it gets on the head or block and you get a steady stream of fumes that come into the car through the ventilation system.
The fuel filter connection may also be leaking. I have had that happen before, same result, a stink in the cabin that is very unpleasant.
Just some ideas, and congratulations on the new son! Jim
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Own:
1986 Euro 190E 2.3-16 (291,000 miles),
1998 E300D TurboDiesel, 231,000 miles -purchased with 45,000,
1988 300E 5-speed 252,000 miles,
1983 240D 4-speed, purchased w/136,000, now with 222,000 miles.
2009 ML320CDI Bluetec, 89,000 miles
Owned:
1971 220D (250,000 miles plus, sold to father-in-law),
1975 240D (245,000 miles - died of body rot),
1991 350SD (176,560 miles, weakest Benz I have owned),
1999 C230 Sport (45,400 miles),
1982 240D (321,000 miles, put to sleep)
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