Hi All, my first post here...Picked up an unmolested 06 JCW with 66k, clean one owner car with extensive records. I bought it as a project car for my 3 boys and I to Mod. We set a budget, did some research and voted on which mods to do. We started with some simple cosmetic ones (stripes, decals, etc.) and then jumped right into installing Headers and Sport Cat ;-). We Just installed the Milltek headers w/Sport Cat...install went OK but have an exhaust leak at manifold, far left on passenger side port, top. We used a new gasket and followed bolt pattern tightening, middle out. Admittedly, we didn't have a torque wrench to fit, so cant say we tightened to exact torque specs. Is the gasket directional? I don't see any markings to distinguish...the only difference is that on one side the port openings seem rounded into opening. Any advice on troubleshooting, tightening, tools, etc.? Also, O2 sensor after CAT is just touching the heat shield w new setup. I have pushed heat shield back as far as it will go....has anyone else experienced this? Is there a way to use an elbow fitting on an O2 sensor. Any thoughts or advice would be greatly appreciated.

Sorry for all questions...I am sure many have been answered a hundred times over...I have looked, but probably missed something.

 

Nice car -

If you used the steel, embossed, shim gasket, you'll most likely need another one.

You can try... Remove the header / gasket, clean the cylinder head surface REALLY well, let dry. With a dry, clean gasket, use some "Copper Coat" spray gasket sealer on both sides, then as you say, from the center out...
Do "two" tightening sequences. One with light, even torque, then to full torque, again, both from the center out to the ends.

OR...you can go to your nearest parts store, and get some "gasket material". It's a dark grey/black, comes in a roll. Use the original header, or the original gasket as a pattern. Cut out a gasket.
Clean the cylinder head well, place the gasket and header, and tighten per above.
This SHOULD work well. I've used this material on both the intake manifold and exhaust headers on MANY cars over the years, all sealing well.

Mike

 

Thanks for the quick reply...actually used the gasket that came with the Racing Dynamics Header (long story but bought that one first and installed but that one was total fitment disaster, so I removed and returned). The Milltek didn't come with a Gasket so I used the RD one, perhaps that's the problem......What should I use to clean the Head? It really was in great shape though, see below.


.

 

A razor blade and "Brake Clean". If you don't have any, normally the big hardware stores carry them, so do many hobby stores. They are cheap.

Most any left over debris will cause leaks when using embossed steel gaskets, in my experience. The softer gasket material that I mentioned is more forgiving, but should...still be clean !

Mike

 

that's a nice mini

 

^^^ Agreed, nice MINI and tidy garage too - love to see both!

 

Thanks for compliments about both. Garage not yet complete...waiting on rest of cabinets and (2) lifts. Will share some pics when finished.

BTW - Was able to correct Exhaust leak with a new Gasket from Mahle. Nowgoing to enjoy the sound of the Miltek Header and sport Cat. Thanks to all for assist.