What's That Smell?
 

Today has not been a good day. Temp has not gone about 49F all day, and my wife is complaining that her 2009 Aura XE "smells" whenever she starts it up - also, its "really noisy, and sounds like a truck".

No trouble lights showing on the instrument panel, and no codes stored in the computer. She is right that there is a smell (engine exhaust) when the car is started, and the sound of the exhaust has taken on a sharp, tinny sound. After driving the car for about 15 minutes, the sound of the exhaust quietens down, and the smell goes away, mostly.

Up on jackstands, and under with a heavy ground pad to keep my tender body off the cold, cruel ground. Exhaust pipe has several fresh scratches right where it drops down from the engine and turns toward the rear of the car. Pipe is not crushed or bent.

20 minutes with a flashlight finally discovers the problem -- the exhaust manifold has developed a vertical crack across the header well above the O2 sensor. Suspect wifey has been doing a little curb-hopping, but won't admit it. Contacted my local Saturn-friendly dealership and explained what I've found.

Was told, "No problem. Casting on several manifolds was found to be weak. Bring the car in, and we'll put a new one on under extended warranty." I'm not going to look a gift horse in the mouth ........

Glad you found the problem. Getting a free fix is a great bonus.

Nothing as good as that GM extended warranty