Exhaust manifold leaking

[Jezza-7]

Has anyone ever had a problem with the gasket not sealing properly?

I altered my system a few weeks back and seemed to cause a leak. Changed the gasket for a genuine VW one and the leak is still there. Even with the system disconnected from the manifold it still leaks.

Any ideas?

[z3i]

Did you tighten it to the correct torque as over tightening can cause it to leak

[dub-disaster]

have you got a flexi in your system?? Some times especialy if you have tried forcing the rest of the system into a position it doesnt naturaly hang i. The engine movment along with thermal expansion can cause the manifold to move .

Other causes can be warped mating faces did you check that the head and manifold flange where flat and square.

[Andy]

Try doubling up on gaskets if you think the mating face has warped slightly.

[z3i]

have you got a flexi in your system?? Some times especialy if you have tried forcing the rest of the system into a position it doesnt naturaly hang i. The engine movment along with thermal expansion can cause the manifold to move .

Other causes can be warped mating faces did you check that the head and manifold flange where flat and square.

i also found without a flexi if you hit a speed bump or something, alot of the force goes straight into the manifold mounting. Which is the reason mine leaks

[Jezza-7]

I will be getting a system made on the car soon as this is sorted and will be getting a flexi out in.

I did them tight but they were not over tightened, think its 15nm torque?

I think it may be as my car is now sitting lower its hit the bumps too often, gonna take the manifold out completely at the weekend and then check for the surface to see how flat it is, if not will try your idea Andy and double it up.

Was gonna use a small bead of that exhaust stuff, holts? but wanna try avoiding that as that not really permanent.