Help. Uncorrectable (it seems) exhaust manifold leak.
 

I recently acquired a 99 Disco II. The number 5 exhaust port is leaking badly. I've unbolted it, and slid new gaskets in; it still leaked.

I completely pulled it, and inspected the manifold for cracks, and saw none. I then sprayed it with carb cleaner, as it dries, cracks become visible, as they are the last to dry. No cracks were found. I'm a welding inspector by trade, so I have an eye for it.

I rebolted on the manifold, this time using Permatex High Temp Copper (Sensor Safe) Gasket maker on the head, and on the manifold, and used the metal gasket too. Basically: Head, rtv, gasket, rtv, manifold. It still leaks, horribly.

I figure i might have a warp on the head or manifold, or both, this is why i used the permatex.

On the other side of the engine, instead of the two hole metal shim gaskets, there are more conventional looking exhaust gaskets, probably a paper metal mix, any idea on a part number for these? I imagine that they might be more forgiving of any warpage.

The noise started out very small. Then after a few missfires and a 20 mile drive to work, it is across the parking lot loud.

I'm about to go gasket-less and just use the permatex to see if I can even change the sound or intensity of the leak.

Is there any chance the head is leaking exhaust? My oil is clean and antifreeze too. The exhaust can be felt on the underside of the manifold @ cyl 5, but gets hot quickly, making it hard to pinpoint.

I've ran my finger along the various surfaces of the head, feeling for roughness, ie a crack. the noise is horrendous, so i should be able to feel it.

also the paper-ish gaskets on the passenger side are four pieces vs two pieces on the bad side.

It's Beyond my depth to offer any real assistance.

But, for what it's worth, I just pulled my heads and found *two* sets of thin metal exhaust gaskets.

Maybe that would help?

so you had 4 sets on each side? two pair?

Crap. Let Engine cool, and went out to "feel around" again. I might have a head gasket bad.

Sounds like it could be. Sounds like you are mechanical enough to deal with it.

LOL. Famous last words...

Silver lining. The dealer I bought it from (As-IS, No Warranty) has offered to buy the parts, or pay for half of the shop repair.

What's the chances the head is true, and will NOT need machining?

Someone had doubled up on the gaskets. One gasket per two cylinders is normal, or two per side. I had twice that.

Sorry for the confusion.

Looks like you have it under control.

Welcome to the head gasket crowd :) Must be something in the air. My heads are out getting machined as I type.

if you can dont use the silicone sealant on the exhaust system the silicone is not good for the O2 sensors and you have 4 of them

I used the sensor safe sealant. It doesn't contain silicone.

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