Rep Power: 0

The exhaust manifold on my '01 cracked the other morning. The hairline crack is about 3" long one side and extends about 2" further to the backside. One continuous crack. Which made my engine run like crap real quick! And I'm trying my best not to fork over what looks like about $700 for one from the dealer. Anyways, being I'm in California I can't get anything shipped to me because of our way too stringent emissions laws here. I know this is a common problem with these manifolds, but I was wondering has anyone, with this same problem, had any success in welding the crack closed? My brother who's been a welder for years says he can weld it for me, but I wondered how long the welded fix would last. I'd appreciate any help! Thanks..

 
Rep Power: 214

What part of the exhaust manifold is cracked is it on the shorty header or the downpipe where the cat is.

Welding will fix it yes, make sure its a good weld though so that it will last. The weld will work because the header is welded to the flange that bolts it up to the motor so it will be like that. And you could just buy a header off ebay or something for cheap.

 
Rep Power: 0

It's cracked in between the 2nd & 3rd ports. Starts just above the sensor location then up over the top & down the backside. Thanks for the reply, my problem now is getting the nut on the far right of the manifold to come off. They put all kinds of things in the way of getting at that. I've started loosening what I can to have enough access to get to the nut and remove it without stripping it!! oy!! :

 
Rep Power: 214

Have you used a small extension on a socket wrench. And ya i know what you mean by trying to get the header off lol try having the k20 in your car now that is some bs.

 
Rep Power: 388

Welding it wont work. And from how you describe it, you have an LX, which has the cat built in.

You can swap to the EX system- an EX header with an EX downpipe with honda OEM cat, and then you'd put whatever exhaust on it you want- of EX trim of course, or have your LX exhaust welded with a flange to mount them together.

How many miles are on your car? Its possible you might sill be covered under warranty (possible)- double check that.

Your other option is to get a used one from craigslist, ebay, the junkyard, wherever.

 
Rep Power: 0

156k miles. I read somewhere that it was questionable if the D17 A1 was included in the warranty coverage you mentioned, 150k or 14 years. Yes the cat is welded to the manifold, nuthins ever simple! I'll be checking everywhere, if I can't find something, (gulp!) it's off to the dealer.........

 
Rep Power: 0

Here's my epilog. After replacing the manifold/cat combo I started the engine, still ran rough. A friend brought his code computer & hooked it up. It said that cylinder 4 had misfired. Everything else seemed ok. Went to remove the ignition coil at cyl-4. It was stuck! It would not budge. Ended up breaking the "head" of the coil to reveal that the shaft part of the coil had expanded. It came out with the aid of a screwdriver and channel locks but snapped half way down the shaft/chamber. What was uncovered after it snapped was solid rubber at the very bottom, it overheated & melted the end of the coil, where the spark plug was (end of the ignition coil is rubber). Scraped the rubber into pieces a & vacuumed it out. That took awhile to make sure it was all out. In the process I found a bent spark plug electrode, broken from the rest of the plug. And the remaining plug just sitting at the bottom easily removed because the spark plug threads were blown out! After cutting new 14 mm threads I installed new spark plugs and now it runs great. I have no idea how long this fix will last so I have my fingers crossed! Thanks for letting me bend your ear!!

 
Rep Power: 0

I heard the same thing before when I had the same problem. Luckily I was able to get one and still have my cracked manifold.

Just curious does this work you think

http://www.alumaloy.net/castaloy_specs.htm