A while back I developed the P2096 code and discovered an exhaust leak at the joint between the exhaust pipe and the pre-cat. It was hard to find the leak since it was hidden under the heat shield shroud on the exhaust. I removed the manifold/pipe assembly (not very difficult except for the oxygen sensor plugs that take a bit of work to release the female plug from the retaining bracket: needs a small pick to reach under the plug and move the locking tab). I'd suggest releasing the rear oxygen sensor plug first to see how it attaches since it's easier to see.

I used a cut off wheel on an angle grinder to remove about a half inch of the heat shroud over the pre-cat to provide access to the crack. My crack ran half way around the pipe, right where there's a crimp-type connection. I wired brushed the area and use my mig welder to run a nice bead around the entire joint. I used short welds to prevent too much heat distortion. The metal seems quite thick around this area and was easy to weld without burning through.

A tip on reinstalling the manifold: get a pair of metric set screws about 1 inch long and fit them in two of the mounting holes in the head, sticking out about half an inch. The setscrews will allow you to hang the new manifold gasket and also locate the manifold so you can easily fit the other bolts. I struggled a bit getting the manifold and gasket in the right position since everything is hard to see tucked in as it is. Once you get some bolts started you can use an allen wrench to remove the set screws.

Final result: exhaust leak is gone, car sounds quieter and my Service Engine light went off after about 8-10 starts over the past week.

Hope this helps others with the similar problem.

Eric

 

What alloy wire and gas did you use?

 

I used ER70S wire with 75/25 Argon/CO2 mix.