The problem sounds like you got the bolts not seated correctly. If you look at the bolts with the springs, the bolts are tapered. If they are not seated properly, the spring will not compress properly and the 2 pieces will not close up.

 

duh

 

had my neighbor look at it, he owns a mechanic shop and told me i had it too tight, but he gave me the seal of approval and told be i did a good job, so i'm done, header finished, never to do another!!!

thanks for all your help and blabbering you guys, really appreciate it.

 

so the only place to get the gasket is from the dealer?

 

I am sorry to say, "Yes" I have been trying to match it up aftermarket wise and still have not found an exact match yet.

But I am still looking. :D

 

what is the risk if the heade is installed wrong or with some gap?

 

Do you guys ever check on ROCKAUTO?

http://www.rockauto.com/catalog/rafr...431767k1021097

2004 SCION XB 1.5L 1497cc L4 FI [1NZFE] : Exhaust : Exhaust Manifold Gasket
FEL-PRO Part # MS96527
Dual Overhead Camshaft Engine
$6.39

I just picked it up but I am not sure what the donut is described as:
Is this the FEL-PRO version of the donut?

FEL-PRO Part # 61124
Dual Overhead Camshaft Engine; Ring $7.67


Really really cheap