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EGR cooler leaking gas on exhaust manifold joint

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New User

Feb 25, 2019, 3:59 PM

Post #1 of 3 (1446 views)
EGR cooler leaking gas on exhaust manifold joint Sign In

Hello car junkies, I’m Darren from the UK, I hope I find you well.

I have a problem with my 2007 VW T5 Transporter and I’m looking for suggestions for a fix.

The problem is that the EGR cooler to exhaust manifold joint is leaking exhaust gases and I’m having a bit of a time trying to seal it.

I noticed that the cast iron manifold joining surface is a little pitted which can’t be helping with sealing the joint between it and the stainless steel egr cooler.

I have another new oem gasket, strange looking thing which basically is two pieces of metal slightly pressed outwards around the aperture and joined with minute spot welds in two places. I suspect it’s design is to do with joining the two dissimilar metals while catering for their differing heat expansion coefficients.

I don’t really know how hot the manifold gets so rather than use a high temp gasket sealer I was thinking about using some fire gum or gun gum on the gasket which will set hard and will stand up to the temps. Thing is with the 2 metals being different and a metal gasket sandwiched between, I’ve no idea how the expansion of the metals will affect the gun gum so I thought I’d come cap in hand to seek advice from people who know better.

So, any ideas how I can get a gas tight seal without removing the manifold and machining the surface flat would be much appreciated.

Thanks everyone,

Hammer Time
Ultimate Carjunky / Moderator
Hammer Time profile image

Feb 25, 2019, 4:52 PM

Post #2 of 3 (1434 views)
Re: EGR cooler leaking gas on exhaust manifold joint Sign In

We are in the US and i don't think we have that model here and I have no idea what gun gum is but you can't hurt anything by trying.

There has to be something bent or deformed in one of the surfaces if it won't seal.

Make sure that is actually the point it is leaking from.


We offer help in answering questions, clarifying things or giving advice but we are not a substitute for an on-site inspection by a professional.

Tom Greenleaf
Ultimate Carjunky / Moderator
Tom Greenleaf profile image

Feb 26, 2019, 12:31 AM

Post #3 of 3 (1412 views)
Re: EGR cooler leaking gas on exhaust manifold joint Sign In

dazifier :
You just need to fill pits for this to seal? Should be doable but unsure of what products you can get that wouldn't crumble? Gun Gum? Not known to me perhaps is a brand or nick-name?
US based site as Hammer said so just fundamentals: The heat there may get to 550F maybe a little more do the math for Celsius if you need to. I've used a product may not be sold anymore but was by Permatex "High Temp" gasket maker is a Silicone product of an "amber/orange color" takes a long time to dry to the touch on the gasket you have not so much by the name or suggestive "make your own gasket" type thing.

Works for me on right after catalytic converters where some applications use a gasket to rest of exhaust must say I don't know the exact temp right there as it's under a vehicle working hard while driving and I'm not about to hang there to measure it - laugh if you will.

It works. It also if you use another product by Permatex also is super high temp silver colored grease sold with brush in the cap stuff the pitting will cease.

Other thought and a maybe? > If nothing else try for a plumbing and heating outlet for a putty used for furnaces not so sure it can stay flexible worth a try.

The product once was made of ASBESTOS avoided almost in anything for any use is or was a heat proof as about anything I can think of. Ugg - once sold by the roll for making gaskets totally may be something like it not as harmful would also be plumbing and heating now near sure only.

Suggestion for now: Trace your new gasket on paper so if a failure you have the shape to try something else. Good luck, you may need it!


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