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Discussion Starter #1
I'm looking to find out what the differences are between the Gen3 and Gen4 exhaust systems are, to see if the SHObros 96-99 Vulcan y-pipe will fit a Gen4 Vulcan.

Mainly, I need to know what the difference is between the G3 and G4 exhaust manifolds is. Rockauto shows different part numbers for Dorman "OE Solutions" replacement manifolds, which are:
2001 Left: 674363, and 2001 Right: 674566
1998 Left: 674365, and 1998 Right: 674362
The pictures on Rockauto comparing the left manifolds look very similar, but it's hard to tell because they're different angles...I'm not sure if Rockauto uses images of the actual parts for everything of if it's just an example.

The connection to the exhaust manifolds is my main concern. I'm also looking for a picture of the underside of a G3 Vulcan showing the connection between the y-pipe and the rest of the exhaust system...search didn't turn up anything. I think there's a picture that might show this in the Haynes manual, but I don't have access to one right now and won't have mine for a couple weeks, and I don't have access to a Gen3 to compare in person.

The plan I'm thinking of is, if the SHObros y-pipe will fit with Gen4 manifolds, I'll remove my 2001's third cat, and I'l come up with something fabricated to connect the y-pipe to the rest of G4 exhaust that incorporates a flex pipe since the G4 flex joint will no longer be there.

If the manifolds don't match up, I could always pick up some Gen3 manifolds from the junkyard, but I don't want to if they either won't fit or aren't necessary. So if anybody has any knowledge of both G3 and G4 exhaust systems, your wisdom would be greatly appreciated so I can decide if making the SHObros part fit is worth it. Thanks :)
 

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From the g3 I've looked at, the rear exhaust manifold exits rear, and downward, from the motor. The g4 rear manifold exits sideways, towards the passenger side. That side of the g4 y-pipe runs up along the accessories, and bolts up to the manifold near the top of the engine. The g3 looked like it had a lot more room behind the engine, where the y-pipe would come up through the subframe, and bolt to the exhaust manifold.

The front manifolds are slightly different, but look like they exit in the same(ish) location.
 

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Discussion Starter #3
Cool....thanks for the info, Mark. :)

Is there any reason I couldn't use G3 exhaust manifolds on my G4? I can't think of any reason off the top of my head why not...I'll have to look at my car later and make sure I'm remembering right that there's nothing in the way of running the exhaust back there instead of off to the side. I can always heat wrap it, which I was planning to do anyway.

I'm assuming the catbacks on both the G3 and G4 are in (at least roughly) the same place since the floorpan is the same. Somebody posted a picture of a flipped over G3 a while ago that probably shows it well enough...I'll have to try harder to find it later.
 

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the only issue I see is the rear manifold, and the egr setup. Both will bolt up to the motor, though.

The g3 exhaust system starts well behind the motor and subframe, where the g4 exhaust begins further towards the front of the car. To use the g3 y-pipe setup, you'd have to cut your exhaust (this includes the flex joint and 3rd cat), and install a flange where the g3 y-pipe exits.

I'm still not sure about the clearance between the trans and subframe, or body, and the exhaust (y-pipe). It seems like the g3 has more room where the rear section of the y-pipe exits. Hasn't been tried before, so i'm not entirely sure.
 

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the g3 ypipe will not bolt up to the g4 manifolds.

You're gonna have to either make a custom g4 pipe, or get a g3 manifold and run a custom egr setup. I also agree w/ mark, the g3 "looks" like it has more room between the engine and firewall as opposed to the g4. I guess me and Ken can compare tomorrow for ya.
 

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Discussion Starter #6
Hmm....looks like I might as well either go custom or wait and see if SHObros makes a G4 Vulcan pipe. Thanks for the info guys...I was about ready to go out and find a random G3 Vulcan, jack it up and go crawling around under it. I don't think the owner would like that too much though :lol2:

To make the G3 pipe work I'd be getting into the price range of getting one custom-built around here anyways, if I can find somebody who'll touch it. :)
 

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I'll bring my camera to Ken's mini meet tonight, my g4, his g3, and you can see the difference. We gotta look back there anyways, he wants to do the 01+ UIM on his 97.
 

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Discussion Starter #8
Sweet...thanks man B)
 
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