Finally got my engine (D16Z6) back together.
Changed TB, WP, Tensioner, seals, Oil pan gasket, VC gasket Dist o-ring, vtec gasket. Is running smooth except I here an exhaust leak, sounds like it's under the heat shield.

I did have the manifold to cat tube off but installed with new flange gaskets.
When I purchased the Honda dealer noted "exhaust needs attention" but no details.

I figure manifold gasket or a crack.

Do these manifolds have a tendency to crack? If so is there a common spot.
i know some cars tend to crack in certain spots.

Just put PB blaster on the shield bolts so I'll get a look at it tomorrow.

 

Really. It doesn't matter if it's common or not or if it cracks in the same spot. YOUR manifold is what we're concerned about.

Have you VERIFIED there is, in fact, a crack?

 

As I SAID I am taking the heat shield off tomorrow. Some cars (Miatas for example) tend to have cracks in the same spot which are hard to see.

having more information rarely causes problems.

but you are true to your screen name.

 

Yeah I know exactly what you are asking.

The location where my exhaust manifold cracked on my D16z6 93 del sol was about one inch to the right of the O2 sensor hole and then curved around the back of the pipe. You really have to take off the manifold to see it because most of the length of the crack was on the back side.

It was hairline on mine you couldn't get your fingernail in it. More like a stress fracture. I didn't really hear mine but I was getting a cel light 41 for O2 sensor.

I put on a cheap set of headers ($60) ebay and it's been good.

Good luck.

Oh yeah, mine is an auto also. How about that.

 

Well I got the heat shield off last night. Couldn't belive how easy the bolts came out. But they spent 24 hours with PB blaster on them.

Anyway, turns out the leak was induced by me. When i put the down pipe off the rear two nuts came out with the studs attached. the one towards the passenger side looked tight but the nut was part way up he stud so it was bottoming in the manifold but there is a distinct gap on that side. But with the heat shield on you couldnt see it.

Guess I'll get new studs and replace all three while I'm in there.

I have a fel-pro manifold gasket and can pick up the flange gakets at Auto Zone.

As far as reassebmly, should i get the 3 flange nuts tight before tightening the nuts on the head? Seems aligning the manifold to pipe is a bit more difficult than the manifold to head?

 

Good news no cracked manifold !
When I replaced my manifold with a header I also got a new downpipe in the deal and new gaskets.
When I reassembled it I found that mounting the loose header to the head and torqueing to spec (everything evenly) was the most important. That's the most critical connection.
Than I attached my new downpipe to the flange on the header pipe tightened it down evenly.
Than I had to attach the other end of the downpipe to the exhaust system.
Here the attachment bolts are spring loaded and you have the slack you need to get the pipes aligned. Even so I had to use channel lock pliers to compress those springs to get the attachment bolts thru the holes to nut them.
In short you'll have the most "slack" at this connection to force things to come together.
Good luck.