Putting my rig back together after a front end tear down and some engine work.

2001 XJ, 4.0HO Inline 6, CA emissions (i.e. 4 O2 sensors, 3 cats)

Ended up having to take of the downpipe off of the exhaust manifold to get the oil pan off.

Anyway, put it all back together, and there was a noise coming from the connection at the manifold/downpipe. Double checked that it was not a crack in the manifold, it's not. Have tracked it down to a leak at the connection between the downpipe and the exhaust manifold. I've tightened and reseated the connections a couple times and cannot get rid of the leak. I know it is the connection because when I loosen/disconnect, the sound gets worse and I can also stick my hand next to the connection and FEEL the exhaust coming out.

Here is the thing - I don't remember there being gaskets between the cats and the manifold. The FSM I have doesn't mention them,but other people online say that theirs says yes for 2001.

With that thinking, I went to Autozone and picked up two #60836 gaskets which EVERY computer in town says is the part I need. It looks right, even the right shape, but they slide right over the top of the downpipe. (So unless they are intended to sit OUTSIDE of the connection and act as a crush sleeve when pressed between the mounting brackets, I don't see how this could act as a gasket!)

BUT -

This is NOT a flat to flat mounting situation -

It looks like this -





The top of the down pipe above the cat is a flared flange like this -



While the bottom of the collector is a rounded end that appears to fit right into the collar/flange, like this -





So the question is - do I actually need a gasket for this style of connection, or not? Have I just not gotten it seated QUITE right? (Or worse, could the collector be deformed? (It doesn't look deformed, but then again, I'm doing all this with the intake manifold still on.)

Any help is appreciated, and if you have better pictures, feel free to add them to the thread.

 

What kind of condish are the motor and trans mounts in?

 

Rock Auto:
VICTOR REINZ F7549 {#52005431}
Seal Ring Type "F"; Graphite/Wire Mesh; Manifold to Exhaust Pipe



Edit:
In your picture it looks like one is already stuck in the manifold.

 

Those may not be his pics...look like stock photos he used as an example...the bottom pic clearly shows that collector is cracked

 

BTW thebyus, it IS a crush sleeve gasket...It is designed to cup in the fitting. And it's a one time shot, if you screw it up, get another, don't try to re-use the gasket.

You're not the only one, I had to do it a few times as well...

 

Thanks Turbo, but I've already tried that one - it's the off brand of the 60836. It's too big. When I try to install into the cupped flange, it actually slides right over the top and lands on the mounting bracket. Pretty sure that that part is for the NON-CA emissions, which only has a single downpipe, instead of the Y. (Or perhaps my system is NOT stock, which opens up a whole DIFFERENT can of worms!)

I measured up mine and and I have 2" OD collectors, feeding into 1.5" ID downpipes. So I'd be looking at a gasket with an ID of 2+" at the top and about 1.5" ID at the bottom.

 

For anyone who cares - just got off the phone with parts department at a reputable dealership - gave them my vin and they pulled up the parts list - it shows NO gasket, nor part number for a gasket. Then, without prompting, the parts guy described my system to a tee - so I am going gasketless at this point - guess I just need to make sure I get it lined up perfectly.

 

some pics of your exhaust may help

 

That's the problem, I have the whole together on the heap!

Closest thing I can give you is this -



or this -



This is what the top of the downpipes look like -



None of these pics are of mine, it's just how it looks.

 

having the same problem three years later. How did you fix it?

 

Just as the counter person said, this system has no gasket. Similar to TJs of that vintage as well.