Exhausted
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Joined: Feb 2002
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From: Rochester Hills MI
Exhausted
I've got little exhaust leaks where the intermediate exhaust pipe flanges attach to the muffler pipe flanges...(both RH & LH connections). Upon startup condensate drips from these joints then starts to bubble and gradually gets burnt off as the system heats up. The reason I looked at this in the first place is that I'm getting a lot more decel popping with my Corsa Touring set up than ever and think this may be part of the problem.
I've tried replacing the gaskets ($7 ea.
from Les Stanford in Dearborn, MI) and torquing the flange bolts to the 37 ft.lb. spec. but still have the leaks. Even though the flanges butt up tight there still seems to be almost no gasket compression...thus the leaks.
I'm thinking of crawling back under the car and doubling up on the gaskets and adding some hi-temp sealer. Can anyone recommend any other solution.
I've tried replacing the gaskets ($7 ea.
from Les Stanford in Dearborn, MI) and torquing the flange bolts to the 37 ft.lb. spec. but still have the leaks. Even though the flanges butt up tight there still seems to be almost no gasket compression...thus the leaks.I'm thinking of crawling back under the car and doubling up on the gaskets and adding some hi-temp sealer. Can anyone recommend any other solution.
Team Owner
Joined: Sep 2001
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From: Lake Elsinore, CA
I wouldn't bother trying to double up on the gaskets since, as you have found already, there is virtually no compression so the flanges would just be further pushed away from each other without sealing the leak. I have tried that in the past. I've found that the mid-section and catback are usually misaligned when this occurs so loosening up the mid-pipe connections and the catback to relieve stress is helpful. Then retighten the connections, working from the front of the car to the back and adjust the catback tips before the final tightening. Worst case you can always use some RTV sealant there but I have never found that necessary at the rear flanges if the system was properly aligned and adjusted.
Team Owner
Joined: Mar 2001
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From: small town in S.E Pa. PA
St. Jude Donor '03-'04
Originally Posted by Patches
I wouldn't bother trying to double up on the gaskets since, as you have found already, there is virtually no compression so the flanges would just be further pushed away from each other without sealing the leak. I have tried that in the past. I've found that the mid-section and catback are usually misaligned when this occurs so loosening up the mid-pipe connections and the catback to relieve stress is helpful. Then retighten the connections, working from the front of the car to the back and adjust the catback tips before the final tightening. Worst case you can always use some RTV sealant there but I have never found that necessary at the rear flanges if the system was properly aligned and adjusted.
Well, Bill . . . I see you are back to your usual self. 
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Joined: Feb 2002
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From: Rochester Hills MI
Thanks for the suggestions Patches 
.
I think I'll try the "lazy" way first and use some sealant. If that fails I guess I'll have to start at the front and work back as you suggest. Dang it.. I'm getting too old to crawl under this car..but still too cheap to let anyone else do it !
For what it's worth I think that I noticed a male/female type of set up on these pipes. The muffler pipe seems to extend slightly beyond the flange joint face, while the intermediate pipe appears to be slightly recessed or underflush with its flange. I think I'll try to get someone to help me take the load off the muffler end while I tighten the flange bolts, but you would think that the 2 flange bolts would draw the pipes together square enough to seal.
. I think I'll try the "lazy" way first and use some sealant. If that fails I guess I'll have to start at the front and work back as you suggest. Dang it.. I'm getting too old to crawl under this car..but still too cheap to let anyone else do it !
For what it's worth I think that I noticed a male/female type of set up on these pipes. The muffler pipe seems to extend slightly beyond the flange joint face, while the intermediate pipe appears to be slightly recessed or underflush with its flange. I think I'll try to get someone to help me take the load off the muffler end while I tighten the flange bolts, but you would think that the 2 flange bolts would draw the pipes together square enough to seal.
Racer
Joined: Jun 2004
Posts: 474
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From: Moncks Corner South Carolina
I had the same problem. So I had an x-pipe installed. When we got the stock pipes off, we saw that the problem wasn't gaskets. The welds at the flanges on the stock pipes had both cracked, letting exhaust through. I was getting puddles on my garage floor after driving it. Installed Corsa x-pipe and that solved the problem.
