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I'm a bit lost as to where they're coming from. Only happens with windows down and seems most noticable at 40mph and under.

I thought the problem would be resolved when I removed and blanked the EGR, as it was clearly leaking with black soot visible on the main body of the vacuum unit.

Still stinks with windows down though...searching the forums the next thing to check seems to be the clamp where the turbo joins the exhaust.
Failing that maybe manifold gasket? I just assumed a blow big enough to gas me would sound louder than that!

Check the exhaust flexi down-pipe they are a common failure and on a turbo diesel engine you don't really hear exhaust leaks as much as you'd expect.

Often the reason the down-pipe fails is due to excessive engine movement because the rear lower engine mount is goosed.

If you get a lump of rag, hold it in your hand and use this to block the exhaust* you should be able to hear it blowing, an assistant should be able to localise where it's coming from.

*if you can get to it, mine still has the original tail pipe and it exits from underneath. The actual tail pipe is a Mickey Mouse fashion accessory...

Thanks for the advice
Is it likely to need a new flexi piece or just a case of resealing with paste and tightening?

Assuming it is the flexi leaking it would have to either be replaced as a full downpipe section including the CAT or cut out and another flexi 'fashioned' in its place.

Here was mine:


You can see the deformation is set and a bit of soot staining where the flexi section had a hole in it.