Exhaust manifold

supercommuter · Post by **supercommuter** » Sat Apr 02, 2011 2:55 pm

I ordered a stock replacement exhasut manifold from rockauto to replace my cracked one. The manifold arrived today, but it looks nothing like what is on my car. It's a completely different shape, it appears to be about 3 or 4 inches shorter than the original, and the O2 sensor hole is in a different position. Plus the gasket set has a sticker that says "Chrysler: 1995-98".

I called them, and the rep swore that it is the correct part, and even despite what the label on the gasket set says, it is the right gasket. Here is a pic of it from their website. and the part # is Dorman 674588, which I'm pretty sure is the correct part#. However like I said, this one looks nothing like what is on my car. It looks as though it may physically bolt up to the head, but because of the difference in length, it appears it's going to be about 3 or 4 inches away from bolting up the the rest of the exhaust. I really don't want to have to take this to an exhaust shop, I was hoping for a direct fit.

Is it possible that the factory manifold is different from what is being sold as the replacement? Or did rockauto screw up and just send me a completey wrong part?

I'm assuming you guys know what a stock one looks like, so here is the pic of the new one:

This pic was pulled from their wesite, but it is the actual part.

heydockyle · Post by **heydockyle** » Sat Apr 02, 2011 3:07 pm

Well it's not a dohc manifold because of the seperate flanges where it bolts to head.

It's not 1gn style because it has 4 bolt flange where meets cat, not 2 bolt.
Early 00 or 01 come with a manifold like this maybe? idk..

What year is your car?

ZeroChad · Post by **ZeroChad** » Sat Apr 02, 2011 3:21 pm

Do you have the R/T (magnum) engine? If so, you have a different header than normal neons.

supercommuter · Post by **supercommuter** » Sat Apr 02, 2011 3:27 pm

It's a 2000. The motor is definitely a 2.0 SOHC. I don't think I have a Magnum. Here is my VIN if that helps...1B3ES46C7YD787852.

Then again, the motor might not be the original for all I know. I'll try to take a pic of the manifold that's on there now.

supercommuter · Post by **supercommuter** » Sat Apr 02, 2011 3:43 pm

Alright, I snapped some pics of my manifold...

heydockyle · Post by **heydockyle** » Sat Apr 02, 2011 3:49 pm

Yep, some 2000 come with a different manifold. They have a name for it, can't quite think of what it's called atm.

alsey_seven · Post by **alsey_seven** » Sat Apr 02, 2011 3:49 pm

ow god thats a ULEV cat..

Those thing are expensive I've been quoted that they cost close to 900.00 I have one since the car is a CA

I would take that bad boy out and only use it to smog your car

supercommuter · Post by **supercommuter** » Sat Apr 02, 2011 3:54 pm

So will the replacement manifold bolt up in it's place? I just would like to know since if I find out after the fact I'll have to put the old one back in until I can get the right one. I'd rather know now than find out the hard way.

heydockyle · Post by **heydockyle** » Sat Apr 02, 2011 4:01 pm

I lied. lol

Danteneon · Post by **Danteneon** » Sat Apr 02, 2011 4:02 pm

You should be able to replace the one on your car with the one you got. Enjoy the additional power

supercommuter · Post by **supercommuter** » Sat Apr 02, 2011 4:03 pm

heydockyle wrote:Your best bet is to take the manifold to an exhaust shop and have them fix it up for you. It will be cheaper then getting another manifold with that ulev setup. The way it sits right now that other manifold will not work.

So are you saying that the manifold and cat are all one piece? It doesn't look that way.

The manifold was only $65, I'd rather just replace that, especially since I'm sure I'll have to pay some sort of restocking fee to return it, than spend a few hundred at an exhaust shop. If the original can even be fixed.

heydockyle · Post by **heydockyle** » Sat Apr 02, 2011 4:31 pm

I've never messed with one. I was assuming it was one piece. Listen to the man above you, Dante. He would know before I would.

supercommuter · Post by **supercommuter** » Sat Apr 02, 2011 4:36 pm

well, I did a search and found this thread... viewtopic.php?p=712302&sid=01b913bd1987 ... 1c6833373d

So the factory manifold has an additional cat built into it? I guess that's what that cylinder is at the end? So according to that thread, my car has two cats, and the O2 sensors are in the maifold before the first cat, and in the pipe between the first and second cats.

So I guess I'm screwed. If I put in my new "direct replacement" manifold, I'll have both O2 sensors before the cat, so I'll probably get a CE. Plus I'll have to pay a shop to connect then new manifold the the pipe, since now it will be a few inches shorter.

Man, I'm so screwed. All I want to do if fix this exhaust leak the easiest and cheapest way possible, and still pass emissions.

NickKo · Post by **NickKo** » Sat Apr 02, 2011 5:45 pm

supercommuter wrote:well, I did a search and found this thread... viewtopic.php?p=712302&sid=01b913bd1987 ... 1c6833373d

So the factory manifold has an additional cat built into it? I guess that's what that cylinder is at the end? So according to that thread, my car has two cats, and the O2 sensors are in the maifold before the first cat, and in the pipe between the first and second cats.

So I guess I'm screwed. If I put in my new "direct replacement" manifold, I'll have both O2 sensors before the cat, so I'll probably get a CE. Plus I'll have to pay a shop to connect then new manifold the the pipe, since now it will be a few inches shorter.

Man, I'm so screwed. All I want to do if fix this exhaust leak the easiest and cheapest way possible, and still pass emissions.

You may want to check the 'For Sale - Parts' section.
I don't know if there is one for sale at the moment, but they come up every now and then.

Also, try your local junkyards.
It shouldn't be too difficult, to 'source' a good used one.

- Nick

Danteneon · Post by **Danteneon** » Sat Apr 02, 2011 6:33 pm

IIRC, the non-magnum non-ULEV manifold has a O2 bung in it like this...

The pic you provided shows the manifold flipped over so I can't see the other side, but does it not have the O2 bung?

Post by **occasional demons** » Sat Apr 02, 2011 7:08 pm

His has the o2 bung for the upstream in the right place, it is the downstream o2 bung that is the problem. The ULEV has it after the mani-verter, but before the normal downpipe cat. So without welding a bung after the downpipe cat, he will get a CEL for a blown cat.

Plus his down pipe is too short to reach the normal manifold. But then a mid length header would prolly fit nicely.

supercommuter · Post by **supercommuter** » Sat Apr 02, 2011 8:07 pm

Alright, so I guess I have three options...

1. Take it to an exhaust shop and see if they can weld the crack.

2. Use the replacement manifold and get a new cat that has the O2 sensor behind it.

3. Try to find a direct replacement for what I've got at a junkyard.

But if my setup was only on early 2000 California cars, it's probably unlikely that I'll find one in a junkyard. I'm sure they're probably pretty scarce.

I guess if I could get a cheap cat that would bolt up to the new manifold I've got, I'd be all set.

Post by **occasional demons** » Sun Apr 03, 2011 10:43 am

I don't think ULEV was California only, but still kind of rare.

Magnaflow has a direct fit cat for just over $200, but you can find other makes for less than $100.

Depending on the place you take it to be brazed/welded, a new down pipe/cat may be cheaper, if you do the removing/installing. But then an exhaust shop may not install anything else but what is on there. They would face stiff penalties if they got caught.

supercommuter · Post by **supercommuter** » Mon Apr 04, 2011 8:56 am

I went to the junkyard yesterday and there was one Neon, the manifold was still there, but it wan't the ULEV type.

So I think I'm gonna keep the new replacement manifold, scrap the ULEV manifold and cat, and then try to find a cheap cat and downpipe with the downsteam sensor it the right place.

I think that will be the cheapest route, and the most direct bolt in.

I posted a WTB ad for a stock cat and downpipe, if anyones got one laying around. Thanks!

Post by **occasional demons** » Mon Apr 04, 2011 9:43 am

www.rockauto.com has an EASTERN CATALYTIC CONVERTERS brand direct fit for $160.79, but IIRC, I have seen that brand on ebay for less.

Or you could have the flex flange cut from your existing and use a universal cat, but then you may as well just have it lengthened.

supercommuter · Post by **supercommuter** » Mon Apr 04, 2011 10:34 am

The thing is, there's nothing wrong with my cat. The problem is the manifold is cracked. I only really want to replace the part that is bad. So since I bought a new manifold, I'm just looking for the easiest way to make this work. It just seems like a lot of money to replace a bad manifold.

Post by **occasional demons** » Mon Apr 04, 2011 12:21 pm

You would need to lengthen the down pipe to fit the new manifold. Whether or not an exhaust shop will do that is a gray area, since they would be responsible for altering the emissions equipment.

You are going to have to:

A: Have the crack repaired, and hope it holds up. Return the new manifold, and take the restocking hit. Or,

B: Buy a downpipe/cat that will work. Or,

C: Have your downpipe/cat/02 sensor bung modified to work.

Ebay options

All are considerably less than a new replacement part.

NickKo · Post by **NickKo** » Mon Apr 04, 2011 11:12 pm

Personally, I would just use this problem as an 'excuse to upgrade' to a header, replace / upgrade the cat, and the exhaust system....... because I am sick like that.

- Nick

supercommuter · Post by **supercommuter** » Tue Apr 05, 2011 3:33 pm

Alright, I've got a line on a used ULEV manifold, exactly like the one that is in my car now, with the built in cat, for $50. If I go this route, it's just a direct bolt in job, swap manifold and be done with it. No exhaust shop, no cutting, no welding. Car remains stock and should pass emissions and no CEL. I can return the new manifold and hopefully not have to pay a restocking fee and get my $65 back for that. Total cost $50.

Alternatively, I've got a line on a used but in good condition standard style (non-ULEV) stock cat and downpipe, for $80. I could then replace my ULEV manifold with the new one I got from rockauto, and bolt up the used cat and downpipe, cut the old cat out, and then just have to have it welded up to the rest of my exhaust. Total cost: $145 + exhaust shop labor to connect new (used) cat to existing exhaust.

So the first option retains my setup, for better or worse, but at least I won't have to worry about a CEL or not passing inspection. It's also cheaper and easier. The only downside I can see is that the cat in the manifold might be shot.

The second option gets rid of the ULEV crap but still should be legal and pass inspection with no CEL. It's more expensive and more work. The plus is that I'll have a brand new manifold, the downside is that the used cat might be shot.

What do you think?

Danteneon · Post by **Danteneon** » Tue Apr 05, 2011 3:46 pm

Option 2. There should be no welding involved since the cat is clamped to the mid pipe. Getting rid of the ULEV set-up and having a new manifold is always a good thing.

Forest Green 2k · Post by **Forest Green 2k** » Tue Apr 05, 2011 11:08 pm

My 2000 bought in Western, New York had a ULEV manifold. Now it has an OBX short-tube.