Parts for your 2005 Mitsubishi Lancer-Exhaust gasket

2005 Mitsubishi Lancer exhaust gasket — what it does and when to replace it

The 2005 Mitsubishi Lancer does use exhaust gaskets. Factory technical references, including the Mitsubishi Motors Lancer Workshop Manual for the CH/CS platform (2003–2007) and the Mitsubishi ASA electronic parts catalogue, show multiple gaskets in the exhaust stream: an exhaust manifold-to-cylinder head gasket, a front-pipe “donut” or ring gasket, and, depending on trim, flange gaskets further down the system. Gregory’s/Haynes-style service manuals for this model range also note that these gaskets are replaced whenever the joint is disturbed.

On the Lancer, exhaust gaskets seal hot gases so they don’t leak at joins. The manifold gasket handles intense heat and expansion at the head, the front donut gasket lets the pipe flex without blowing out, flange gaskets keep things tight at the cat and muffler connections. When they fail, you’ll often hear a ticking or chuffing on cold start, smell exhaust odour in the bay or cabin, or spot black sooty marks near a joint. A leak ahead of the oxygen sensor can even skew fuel trims and upset economy.

• Tell-tale signs: sharp tick on start-up, fumes/odour, soot at a flange, droning note, or faint whistle under load.
• When to replace: any time a joint is separated, if a leak is detected, or if age/hardening is evident.

Replacement on a 2005 Lancer is straightforward but benefits from good prep. Use the correct gasket type for the joint (MLS or graphite/steel manifold gasket, crush-ring/donut for the front pipe). Clean mating faces, check studs and spring-bolts, and fit new hardware if corroded. Install the manifold with the specified torque and tightening sequence (centre-out as per the workshop manual), then warm the engine and recheck for leaks. Avoid general exhaust paste or RTV near the O2 sensor or cat—most Mitsubishi procedures call for clean, dry assembly with new gaskets, no sealant. A light touch of high-temp anti-seize on threads (not on sealing faces) helps the next service, if permitted by the manual.

As part of routine servicing in Australia and New Zealand, it’s worth a quick listen on cold start and a visual check under the bonnet and along the front pipe every 10,000–15,000 km. Catching a small leak early protects the oxygen sensors and catalytic converter and keeps the Lancer running sweet as.

Popular question: Where are the exhaust gaskets on a 2005 Mitsubishi Lancer?

Most have three main points: the exhaust manifold-to-head gasket at the engine, a crush-ring (donut) gasket where the front pipe meets the manifold or catalytic converter, and a flange gasket further rearward depending on model. Evo and 2.4 variants still use the same basic gasket locations.

Popular question: Can you drive with a leaking exhaust gasket?

Short trips might be possible, but it’s not a great idea. A leak can pull fresh air into the exhaust, upsetting oxygen sensor readings, increasing fuel use, and risking catalytic converter damage. There’s also the safety angle—fumes and carbon monoxide can creep into the cabin. Get it sorted promptly.

Popular question: Do exhaust gaskets need sealant on a Lancer?

No. The Mitsubishi workshop guidance for this era specifies new gaskets installed clean and dry. Don’t use RTV or exhaust paste near sensors or the cat. If anything, only apply a dab of high-temp anti-seize to fastener threads, not to the sealing faces.