There seems to be a leak of exhaust fumes coming into the cab of my 2007 Fiat Ducato 160. The headlining and bulkhead interior trim is covered in soot deposits. I have taken it to a Fiat dealer who have confirmed that there is a leak coming in through the air vents but they do not know exactly where. The dealer now wants to take it in to strip it all down but it is now out of warranty and its going to cost a fortune and I cannot afford to have it off the road. I have already ordered the new headliner and bulkhead trim and am in negotiations with Fiat to reduce the approx £250 for these 2 parts Would be grateful for any comments/ideas etc. I have attached some images.

Huge health risk, does the exhaust sound noisy? Especially under the engine cover? I've seen Threads about leaking or damaged couplings to the EGR.

Oh & Welcome here!

I have checked the exhaust and all seems ok. The dealer had it up on a ramp looking underneath etc but could not see anything amiss. The engine does not seem noisy, in fact the van runs like a dream. Where abouts is the couplings/egr valve etc.

It probably looks something like the below, mounted high up on the engine.
http://www.bing.com/images/search?q...A18778E8328968BDE47598419&first=0&FORM=IDFRIR

Any exhaust leak around here should be easily visible by the build up of soot you have in the cabin.

My best guess would be the joint between the exhaust manifold and the down pipe; second guess would be the manifold to the block, not so likely is a cracked exhaust manifold, the crack usually closes up as the manifold gets hot and expands.
If it’s not noisy then it will be a small leak which is a pain to find.
The best way I know is cold engine dark night half revs and slip a lead light underneath the engine and look for fumes, start by looking down from the top especially the downpipe joint and manifold to block joint.
And as previously said look for soot marks.
Good luck

Temporarily block the end of the exhaust pipe with leather gloved hand (or rag) while the engine is idling. You should be able to see and hear where the leak is then.

Thanks for all the above. I will start to check out the posts. I have now been contacted by Fiat customer care less and they have told me as it is out of warranty and has not been serviced by Fiat they will not contribute to the cost of new headliner and bulkhead. I sent the above images and they admitted that nobody at Fiat has looked at them. I shall now try Trading Standards as this could have been fatal.

i had same problem with my 160 multijet,i was a cracked manifold,hope this helps.

have a look at where the gear cables go through the cab floor and check the seals, another good place to check is under the drivers seat for holes meant for cables etc no being sealed correctlyas i had major exhaust fume entry when stationary and vehicle ticking over but it really sounds to me that some where on the heater / ventilation system is sucking it in and blowing it up behind the body trim and panels when fans are blowing creating the soot marks as it is forced out around different fittngs like radio /interior lights inserts... as for fiat not being interested that is just criminal negligence on there part as to produce marking as shown in pics indicates major cab environment pollution and most descent mechanics should sort this type of contamination out very quickly.as there are not too many spots in the vent systems where this can be picked up from... best regards ken.

mazkenandco said:

... as for fiat not being interested that is just criminal negligence on there part as to produce marking as shown in pics indicates major cab environment pollution

Click to expand...

Agreed. I cannot understand how the owner(s) could not pick this up until 4 years later.
I hope Patsy has not been driving in the cab for this time. Diesel particles (soot) is the worst air pollution health hazard.