I have a 2003 Evo and I have an exhaust leak (mods in sig). I can't pinpoint where it is so I started by changing the gasket between header and manifold. That didn't help any so I changed the donut gasket for the downpipe and reinstalled with the stock downpipe. Still no help. My question is this, can anyone give me an example of the type of sound a cracked header would make? I have the DC sports header and I am sort of worried that it might be cracked. I am taking it off and inspecting it tomorrow. I am so frustrated that I might even just throw the stock mani back own to makes sure the leak is fixed. I am also going to take off the downpipe, clean the surface where the gasket meets and use some gasket sealant. Any other options or thoughts here? I am just really getting frustrated. Is there an easier way to pinpoint the leak? OH, and after the car warms up some, the leak seems to get slightly better. Like the expansion from the heat is helping seal it...that is why I though gaskets. Is this also a symptom of a cracked header? Thanks for any info.

 

DO NOT use gasket sealant...NEVER.. the stock gasket is stainless and they pretty much never leak on any type of vehicle that has stainless steel gaskets. Use a long heater hose and put it up to your ear when you start the car when cold.. Then put the other end of the hose around the exhaust until you hear the leak. Sounds stupid... But it works.

 

Check the gasket between the manifold and the turbo. Just feel around while the car is still cold......remember you wont have much time

 

Yeah, I have tried that around the turbo and I didn't feel anything. You are right though, sucker gets hot FAST!

 

look for any carbon build up at the flanges also