Aimed at the exhaust gas leakage between the joint of exhaust manifold and turbocharger on one gasoline engine,the factors that may lead to the sealing failure were analyzed from test conditions and failed parts.The reason causing the sealing failure was analyzed by using Abaqus FEA software,and a new optimization schemes,including strengthening the structure of turbocharger and optimizing the springback performance of turbocharger gasket were put forward.The optimized gasket and turbocharger were validated to be remarkable,and the gas leakage problem was effectively solved.