Exhaust replacement error....
 

I replaced the entire exhaust system of my second gen today, and got it all on without a hitch, until I turned the key. Now the car won't start, where it had started before. But I'll start at the beginning and hopefully someone can tell me what went wrong.

About three months ago my car went illegal and needed to be safetied in missouri. It didn't pass due to numerous exhaust leaks and my pre-cats weren't even connected anymore due to rust. I parked it in illinois so that I could dodge the property tax and so it wouldn't get impounded due to apartment rules, and it sat there only getting started on a rare occassion. Then I bought a Corksport single exhaust, stainless steel to prevent rust, and a mangnaflow OEM catalytic converter to replace the pre-cats with a straight piping into the new catalytic converter. In it sitting there so long the battery died so I replaced that as well.
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I drove it onto ramps and jacked it up. It started fine here.

Removed all the exhaust pieces basically as a whole. They were rusted together and rusted through in many places. It's an 87, and none of it had ever been replaced. One of the bolts on the exhaust manifold stripped in removal, but I got it all off. I also had to remove the air splitter connected to the cat from the hose in the engine bay. Hung the Corksport sytem first due to waiting for gaskets at O-Reileys* and let it sit over night. It was a nice night and I was tired so I left the hood open, and drove home. Then I came back out the next day and installed the cat and the piping to the manifold with gaskets in place. I had to use hosing on the air splitter since that is what was being used in the car beforehand. But it was all on as it should be by the looks of it. I try to start the car, and I get no response, though I still have headlights, and dash lights working. My radio works as well. I don't even get a response from the starter. I do however get a hissing as if air is escaping somewhere and the smell of gasoline. But there is no leak coming from under the car that I can see. I checked the wiring that I was working around, which isn't much, and it all seems fine, but I may have missed something.

Anyone know what might be happening here?

So the engine doesn't crank at all?

Check the small starter cable (black/yellow) with the black connect that is supposed to go to the solenoid on the starter. It may have been bumped off.

Check the big starter cables. Maybe they are corroded?

Tap the starter with a hammer. Perhaps it is stuck. Don't damage it while doing so but it may take a few good blows.

And then unflood the car. :)

The smell of fuel is worrying though. Carefully inspect the area around the pulsation damper (rear of engine under upper intake) for leaks.

Thanks I'll check on those first thing tomorrow. :)

Got it started, now I need to replace the exhaust manifold. Anyone know of a good place to pick one up. It's an '87 non-turbo... Dealer wants 313 for it.

Why do you need to replace the manifold?

I'm still a little new to this, but where the first pipe leading to the catalytic converter connects with the engine, it's leaking exhaust pretty bad. Makes the new exhaust sound like crap and it won't pass safety. If you have a better idea then replacing the manifold I'm all up for it.

EDIT: It's the manifold. I've been reading the Haynes repair manual and it's leaking from up around the manifold. I haven't removed it to inspect it yet, but it's blowing pretty hard out of it. Could it just be a bad gasket?

http://www.nopi.com/dsp_parts.php?vs...t%20-%20Header

I'm thinking of just installing a header, but not sure if this one is the turbo version or not. Has anyone bought this and can tell me?

if your looking for a stock exhaust manifold check your local FS forums or CL for 2nd gens getting parted out or call local junkayard. IDK if picknpull is out there. Usually stock manifolds dont go bad like that.

Try replacing the gaskets first and see if that does it. The manifold->precat gasket is ~$15-20 at the dealer vs $313 for a new manifold (and you'll still need to get new gaskets :P).

The link doesn't work, but some digging on the Nopi site shows you've tried to show a listing to Pacesetter headers. I haven't heard one in person, but many of the reviews from a quick search aren't positive:

https://www.rx7club.com/2nd-generation-specific-1986-1992-17/pacesetter-headers-good-n-30484/
https://www.rx7club.com/2nd-generation-specific-1986-1992-17/pacesetter-header-609211/

It may be a bad gasket. Check the flatness of the flanges with a straight edge. If a gasket has blown out in the past, the flanges are probably warped. Any machine shop can flatten them, but the cost may exceed the cost of purchasing a good used manifold. Then again, a use manifold might have warped flanges as well.

The page you linked to was blank, but if you want to install a header, I suggest on of the Racing Beat stainless headers. Most won't bolt up to your stock exhaust so you may need to have an exhaust shop fabricate a midpipe. When you install the header and remove the cats, you will also need to install an ACV blockoff plate and then figure out a way to activate your aux ports. I suggest keeping the air pump and driving the ports off of the pump.

So no pacesetter then... I'll look into the 16130 racing beats. I've got a magnaflow cat that was a direct OE replacement, but it took out the precats, would the racing beats hook up to the stock flange? or would I need to take it up and get it welded together by a professional?

The Pacesetter headers are crap.

Most of the headers, including RB, are longer then the manifold/precat assembly. You'll need to have an exhaust shop make the cat fit.