I have a 2005 Pacifica Touring 3.5l. After replacing the starter I was putting the front exhaust manifold back on and I couldn't get the donut gasket to seal. It blows out exhaust all over. I noticed it fit very very loosely but it was the same exact size as the old one, also I double checked part # from the dealership so I know it was correct. I spent 4 hours re-seating it over and over again, finally getting it to the point where the car didn't sound like a dirt bike. About a week later it's leaking again. The bolts are tight, they are brand new stainless bolts, I even popped the head off of one at one point. I tried running it a little loose and that didn't make a difference. Tried another new gasket, tried the old gasket. I can't get anything to stop this exhaust leak. I'm going to try some exhaust gasket sealer tomorrow. Even if that works, why is this so difficult? I've never had so much trouble with a simple donut gasket!

 

That really sucks but I've always followed this: whenever there is a gasket, if its no good, ALWAYS USE GASKET MAKER. I've been doing that for 4 years on my 98' Cirrus and never a problem. That would be the way to go my friend.