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post #1 of 5 (permalink) Old 12-17-2013, 07:33 AM Thread Starter
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Still Have an Exhaust Leak

Well, I thought I fixed it, but it came back and haunts me while driving. I replaced the manifold-downpipe gasket, sealed it nice and snug. I took out the header and inspected it, no visible cracks found at all.

I did however notice that where the manifold bolts up to the engine, I used a brand new OEM gasket, that where on cylinder 1 exits, the gasket is square and the header comes down at a curve, exposing the gasket. I can also check on the header a "dummy" o2 sensor was put into the hole and may try for my o2 wrench and ensure that its secured well in there without stripping it.

Any suggestions? Go back to stock manifold perhaps?

2009 Cobalt LS XFE U74
Mods: K&N Typhoon Intake, Option Cat-Back Exhaust, Cosmo Short shifter, Maxxim Ahead 17X7's, MPx shorty antenna, FE5 Strut/shocks, Tein S Techs, Moog endlinks, Moog spring seaters, ZZP shorty header, LSJ downpipe, LNF front grille
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post #2 of 5 (permalink) Old 12-17-2013, 07:35 AM
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well switching back to stock manifold and seeing if the problem persists will rule out the manifold for you

WA636R - Switchblade Silver Mt 09 Sedan LT 2.2L LAP......Auto!

MODS:Fe5 TC Shock + Struts\Moog Endlinks\YYZ V1 Springs\SC Gunmetal Wheels. Badmab Shorty Header\GMPP Performance Exhaust\ZZP 2.5 Catted DP\K&N Drop-in filter\High Flow Intake Tube. Gen4 Headlights\6K Low Beam HID\LED 3rd Brake Light\LED Turn Signals,Plate,Trunk, Dome, Reverse, Side-marker\ Debadge "LT" & GM fender badges\Shorty Antenna

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post #3 of 5 (permalink) Old 12-17-2013, 08:00 AM Thread Starter
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I just torqued every bolt down, found 2 studs that were loose. So I tend to believe that the header-engine gasket is ka-put! It sounds like its dead on where that cylinder 1 is on exhaust port. Looks like I have something to do tomorrow besides tonight's Z32 (fairlady twin turbo) work :(

2009 Cobalt LS XFE U74
Mods: K&N Typhoon Intake, Option Cat-Back Exhaust, Cosmo Short shifter, Maxxim Ahead 17X7's, MPx shorty antenna, FE5 Strut/shocks, Tein S Techs, Moog endlinks, Moog spring seaters, ZZP shorty header, LSJ downpipe, LNF front grille
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post #4 of 5 (permalink) Old 12-17-2013, 08:14 AM
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its all worth the headache, just in case anyone else has that problem

WA636R - Switchblade Silver Mt 09 Sedan LT 2.2L LAP......Auto!

MODS:Fe5 TC Shock + Struts\Moog Endlinks\YYZ V1 Springs\SC Gunmetal Wheels. Badmab Shorty Header\GMPP Performance Exhaust\ZZP 2.5 Catted DP\K&N Drop-in filter\High Flow Intake Tube. Gen4 Headlights\6K Low Beam HID\LED 3rd Brake Light\LED Turn Signals,Plate,Trunk, Dome, Reverse, Side-marker\ Debadge "LT" & GM fender badges\Shorty Antenna

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post #5 of 5 (permalink) Old 12-17-2013, 09:06 AM Thread Starter
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yeah, I will get to it tomorrow morning, picking up part in a few minutes for the new gasket and going back to stock, tsk tsk ;(

2009 Cobalt LS XFE U74
Mods: K&N Typhoon Intake, Option Cat-Back Exhaust, Cosmo Short shifter, Maxxim Ahead 17X7's, MPx shorty antenna, FE5 Strut/shocks, Tein S Techs, Moog endlinks, Moog spring seaters, ZZP shorty header, LSJ downpipe, LNF front grille
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