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Old 09-10-2014, 06:27 AM   #1
runner19
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Default Exhaust gasket leak

2002 WRX sedan 5mt 70 000 miles OEM exhaust manifold and uppipe

I had an over fueling issue, which we traced to a leaking gasket.

I had a leak at the right exhaust manifold and the cross over pipe.(the one with the funny gasket(has a triangle shaped piece sticking out of the manifold.)

I bought new uppipe, manifold to headers, cross over pipe gaskets.

I used soapy water. It is still leaking at the same joint.

It is leaking where the flange faces the radiator.

These are the x layer metal gaskets from subaru. I did not use any liquid gasket-prematex.

Torqued all to 40nm.

It is not leaking any where else

I cleaned all the flanges prior to reinstall. Rubbed it down by hand with 400 grit paper and it was smooth.

Tighten it a bit at at time with a 1/2 rachet. Tightened it as tight as possible with a 1/2 ratchet. Still leaks. It have yet to drive the car on the road.

It tightened it a bit more with a power bar. But it is getting better , but still leaking.

How much can I tighten the nut, with out deforming the flange.

Note the top nut is very hard to reach with the manifold on the car.

Dealer does not have stock of new gaskets.

I would prefer not to drop the manifold again.

I would appreciate any advice.


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Old 09-10-2014, 07:29 AM   #2
Subadrews
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honestly i say just drop it again and use the copper gasket maker, in addition to my metal gaskets i put on there, i too had a exhaust leak and it made my turbo spool soooooooo slllloooww. that stuff usually does the trick, also the torque specs would help. here ya go.

Last edited by HinshawWRX; 09-10-2014 at 04:53 PM.
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Old 09-10-2014, 07:51 AM   #3
runner19
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Hey thanks for the reply. I did torque it to 40nm first.

That means all new gaskets - right?
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Old 09-10-2014, 08:46 AM   #4
fastnoypi
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if you have your old gasket around, you can spray it with copper gasket spray and double up with your newer existing gasket.
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Old 09-10-2014, 09:17 AM   #5
shamrock 05
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Quote:
Originally Posted by fastnoypi View Post
if you have your old gasket around, you can spray it with copper gasket spray and double up with your newer existing gasket.
DONT use 2 gaskets . If you dont wanna buy new gaskets then remove the old one. Put copper gasket maker on both side (a good amount), reinstall and tighten the bolts down nice and tight.


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Old 09-10-2014, 09:30 AM   #6
fastnoypi
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Quote:
Originally Posted by shamrock 05 View Post
DONT use 2 gaskets . If you dont wanna buy new gaskets then remove the old one. Put copper gasket maker on both side (a good amount), reinstall and tighten the bolts down nice and tight.

doubled gaskets will work in the OP's situation and would be a longer lasting solution. OP already used a new gasket. Making up the space that the OP needs with gasket maker will blow out once it gets red hot.
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Old 09-10-2014, 02:48 PM   #7
Subadrews
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as long as they are relatively new or lightly used i would use them, and the copper stuff.
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Old 09-11-2014, 12:59 PM   #8
runner19
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Okay, I could not locate permatex. I got some loctite ultra copper gasket maker(101br).

Looks like similar stuff, good to 700F

I am going to give it a shot tomorrow

Thanks guys
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Old 09-11-2014, 01:34 PM   #9
fastnoypi
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Quote:
Originally Posted by runner19 View Post
Okay, I could not locate permatex. I got some loctite ultra copper gasket maker(101br).

Looks like similar stuff, good to 700F

I am going to give it a shot tomorrow

Thanks guys
Welcome to give it a try, though average exhaust temp is around 1450F.. if the motor is tuned well, you'll be hitting near 1600F @ wot. That stuff will burn up quick.
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Old 09-12-2014, 03:23 AM   #10
runner19
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Yeah I understand what you are saying.

But permatex is also rated at 700F
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Old 09-12-2014, 06:25 AM   #11
runner19
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Update flanges warped. Had them skimmed. Still off a bit when I checked it with my straight end.

Has anyone used Holts fire gum rated to 1000 C

Last edited by runner19; 09-12-2014 at 07:38 AM.
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Old 09-12-2014, 07:37 AM   #12
runner19
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dup post
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Old 09-13-2014, 03:05 PM   #13
runner19
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Update. Leak is gone.

I had the cross over pipe flanges(2) skimmed. I reused the old gaskets and added some loctite Ultra copper high temp gasket maker. (similar to permatex. loctite and permatex used to be one company)

Torqued it to factory specs. leak gone.

Notes.

The flanges on the exhaust manifold(L/R) where straight. Only the cross pipe flanges had warped.

You do not need to drop the entire exhaust manifold to do this. You can unbolt the crosspipe and it drops out. All 4 bolts and nuts where easily accessible.

I left it for 24 hours to cure, before startup. I had to go to work. No choice on my part.

I am going to watch it.
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