Saturn Ion Exhaust Manifold

[WolfmanDave]

Originally Posted by Red07SSNA

My .02 -- Don't use it. It won't seal the same against the cylinder head as the cast iron manifold or aftermarket headers.

I probably won't use it however, I do have to disagree with your assumption that it won't seal against the cylinder head as well as the cast iron manifold. Both the Ion and Cobalt have the exact same Ecotec motor. This manifold seems to be one of several differences. But, as long as you use the exhaust manifold gasket designed for that manifold, it will seal just fine.

The only evidence I have to prove this is my roommate finished putting the Ion Ecotec into a Cobalt and used the Cobalt's exhaust manifold. I kept the Ion manifold. He test drove it for 15 miles and there was no exhaust leak.

[Red07SSNA]

Originally Posted by WolfmanDave

I probably won't use it however, I do have to disagree with your assumption that it won't seal against the cylinder head as well as the cast iron manifold. Both the Ion and Cobalt have the exact same Ecotec motor. This manifold seems to be one of several differences. But, as long as you use the exhaust manifold gasket designed for that manifold, it will seal just fine.

The only evidence I have to prove this is my roommate finished putting the Ion Ecotec into a Cobalt and used the Cobalt's exhaust manifold. I kept the Ion manifold. He test drove it for 15 miles and there was no exhaust leak.

I didn't mean that it won't work -- see the open area where the head-to-manifold gasket goes? You'll have exhaust gas in there where you don't need it -- unless you stop up the opening somehow.

[WolfmanDave]

Oh, I gotcha now. If I were to use it, I would weld a plate over that area.

I don't think you get it... the SAI manifold is not any better than the stock 05-06 one. It just looks different b/c it was custom made to work with the SAI. Go look at a 07 or 08 Cobalt 2.2... it's the same manifold.

That thing is not some sort of half-assed header... if anything it probably flows worse than the stock cast manifold. Just toss it in the trash and we can move on from this whole silly discussion.

[WolfmanDave]

Originally Posted by SilverStreak

I don't think you get it... the SAI manifold is not any better than the stock 05-06 one. It just looks different b/c it was custom made to work with the SAI. Go look at a 07 or 08 Cobalt 2.2... it's the same manifold.

That thing is not some sort of half-assed header... if anything it probably flows worse than the stock cast manifold. Just toss it in the trash and we can move on from this whole silly discussion.

I think you hit the nail on the head. This is EXACTLY the information I was looking for. Looks like I'll just cut off the tubes and keep the flanges. Maybe I'll get some custom header designed for my dream setup a couple of years down the road.

Oh, and I just went outside to check my '08 2.2 Cobalt. I have the cast iron manifold.

[Montecarloman]

Don’t throw it away just yet, it looks like an ok piece. Really you'd need to measure the ports and compare them to the cast iron one. The SAI port can simply be plugged off with a block off plate. I'd be very interested to see if the collector looks like the iron one for the L61. Can you clean off the collector and take some more please?

[WolfmanDave]

Originally Posted by Montecarloman

Don’t throw it away just yet, it looks like an ok piece. Really you'd need to measure the ports and compare them to the cast iron one. The SAI port can simply be plugged off with a block off plate. I'd be very interested to see if the collector looks like the iron one for the L61. Can you clean off the collector and take some more please?

Sure thing. I'm going to bed right now, but I'll take some pics tomorrow and post up then.

well... any new developments?

if anything why not look for a LSJ exhast manifold? it flows better than the 2.2 one.

[WolfmanDave]

The port is oval and is 4 cm across and 2.5 cm tall. The collector measures 5 cm in diameter. Anybody got a cast iron one laying around they can take measurements on? I'd be interested to see measurements on an LSJ manifold and an extrude-honed LSJ manifold.

[Montecarloman]

One of the guys at my shop had one, but he threw it out a few days ago, Doh. Is it a round 5 cm at the collector or is it shaped like a D?