For the problems of flange deformation at high temperature and poor compression-recovery performance of the gasket on turbo engine exhaust system, the flange structure optimization method and the multi-bead gasket structure design were proposed based on CAE calculation and gasket test data. Robust and durable sealing performances were validated by engine bench test and vehicle durability test. The flange design was optimized by means of softening exhaust manifold partial flange to achieve consistent rigidity, and the gas leakage problem between exhaust manifold and turbocharger was solved. According to inner media pressure and flange deformation in thermal cycle, different bead structures were designed on different sealing zone, and robust and durable sealing performance between exhaust manifold and turbocharger was achieved.