02 TL type-S / DC Header:


Made sure the F is in the Fornt and the R is in the Rear. However, these were the steps so far and no luck:

Left both manifolds loose
Connected manifolds to down pipe
connected down to exhaust
went to tighten the manifolds down and they were not flush with the engine and didnt want to tighten too much more as they might have snapped. At this point I was still able to move the manifold gasket.

So we thought maybe they were on backwords (manifolds). Removed them, confirmed F in front and R in Rear. P.S it was nice how DC welded over the left code to see if it's and F or an R. Well, it looks like they were installed in the correct F/R fashion based on the label markings.

Put the manifolds back on tight
tried to connect dp....wouldnt line up to DP holes.

Please advise ASAP

Thank You

 

just for grins did you try switching them around to see if they fit that way ( i dont remember them having F and R on them)

 

Just had to tighten them down alittle bit by little on each nut. Now the other major issue, front manifold gasket. Used the DC provided seal and that provided a nice leak. Removed it to add made up gaskets from a sheet we bought. The DC one was blown out only after 10 minutes. We built up 4 gaskets from the sheet cut outs and there was still a leak. Please provide a solution to resolve this; either copper gasket and/or copper w/permaseal...any thoughts?

 

addingn gaskets wont help if its not seated properly. Did you try switching them around to just double check that they are infact where they are supposed to be? If they arent lining up tobegin with they never will. You may have to contact DC and get new ones

 

The manifold's were in the correct place. And if they were switched (front in read and read in front) they would be WAY off. Now we just need a gasket solution. On the DP to exhaust, we use the DC one and there was a leak. So we used the DC provided one as well as 1 from the sheet...no leaks. It just blows my mind that DC would sell a product that could go bad in under 10 minutes (gasket). I myself have the DC race header on my RSX -S and never has any gasket issue. I think the 2 -vs- 3 bolt theory might fall into this solution. Maybe remove manifolds and DP and weld on a 3 bolt setup for a 100% proper solution. All I know is that with that fron manifold leaking, alot of power loss and very loud. Sounds like a V8 swap lol.

Calling out all DC owners that their header DO NOT leak....what di you use for gaskets?

 

i have copper gaskets on my DCs....search, there are many threads on where to buy these.

 

Copper Pro gaskets have been ordered for my dc headers. Does anyone have any experience or knowledge of possible double-stacking copper gaskets if a leak is still found after replacment?

 

it there is a leak im sure another gasket isnt going to fix much.

 

Copper gasket plus permaseal
Copper gasket plus gasketmaker


Which would be a good solution if the copper one still leaks?

 

When did you actually receive your headers? I've had the same problem with leaking as you, and for a while, double-gasketing (using more DC-supplied gaskets) worked, but they ended up leaking after three weeks.

I put in the SCE copper gasket, but that leaked too. I didn't try double-gasketing the SCEs. I complained a second time to DC Sports, and they sent me some new gaskets. These new ones are thicker than the originals and even the SCE ones, plus have a steel o-ring. I had the shop double-gasket the front header, and put a single gasket on the rear. It's been about a week now with no leak.

I'll take a pic of the gasket I have left (they sent me four). DC Sports really seemed to care about this leaking problem I have, and came through with a solution that's working so far.

 

So is the actual problem with teh leak where it meets the manifold? or the Y pipe conection

 

It is where the manifold meets the downpipe in the front.

 

Huh? The manifold is on the engine, then the header flange, then the 3 pipes which terminate at the collector. The collector connects to the downpipe/Y pipe.

Is the leak at the engine or where the collector connects to the Y pipe?

 

This is the new collector gasket I got from DC Sport about two weeks ago, next to a burned out first gasket they supplied me:

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It's also about 5x thicker than than the original. It's metal on both sides, with a steel o-ring. I've had these in for about a week now. So far so good, but only time will tell if this is a solution.

 

Engine - front manifold - 2-bolt flange - gasket - LEAK - 2-bolt flange - Y-pipe.