1998 4.0 swap into 2000

So i ran into another problem today. I have all my o2 sensors i just didnt realize they were up on the exhaust manifold... So heres my question because i cant use the 2000 manifold on the 1998 what do i do about the two upstream cats that are built in to the exhaust manifold?
 
If you have the two precats and the 4 o2 sensors, 2 before the precat and 2 after the precats then there is no 5th o2 sensor behind the main cat.

This is what i have any ideas on what i can do to relocate them so that they will agree with a 1998 motor that consists of 2 o2 sensors one on the manifold one after the cat?.. I was looking at it and it looks like the harness can be swapped out that holds the wiring for the o2 sensors it appears to go from the pcm to the injectors and then down to the o2 sensors and back by the transmission..:dunno:
 
You'd have to swap the ECU and wiring harness to make it work with the older O2 sensor setup, unfortunately. I'm not even sure if that's legal for over the road vehicles.

What I would do is install additional O2 sensor bungs in the older manifold. Can buy them at speed shops and on summit racing, and it's a ~5 minute weld job. Just make sure you don't locate them somewhere they will run into the intake manifold when you install it.
 
You'd have to swap the ECU and wiring harness to make it work with the older O2 sensor setup, unfortunately. I'm not even sure if that's legal for over the road vehicles.

What I would do is install additional O2 sensor bungs in the older manifold. Can buy them at speed shops and on summit racing, and it's a ~5 minute weld job. Just make sure you don't locate them somewhere they will run into the intake manifold when you install it.

I thought about that but what i am worried about is passing Pennsylvania emissions. Wouldnt that throw the check engine light cuz it has the pre cats and o2s?
 
What I would do is install additional O2 sensor bungs in the older manifold. Can buy them at speed shops and on summit racing, and it's a ~5 minute weld job. Just make sure you don't locate them somewhere they will run into the intake manifold when you install it.
The older manifold won't work with a 2000 down pipe with the precats. The precats are in the down pipe, not the manifold.

I thought about that but what i am worried about is passing Pennsylvania emissions. Wouldnt that throw the check engine light cuz it has the pre cats and o2s?
That will throw a check engine light and you probably won't pass inspection.

You have two options.
1) use an earlier manifold/ header and have the precat O2 bungs welded in, but the manifold has to be a tri Y style so the bungs can be welded so the front O2 sensor monitors the front 3 cylinders and the rear O2 sensor monitors the read 3 cylinders. Then you would have to cut your stock down pipe off with the cats and have a custom down pipe bent up. Once that is done you need to do something about the after cat sensors. Sim them out in some fashion or put them after the main cat, which may not work. Removing the precats is also illegal.

2) Get a 2000+ header and hope it covers the 0630 head ports. I have not verified this myself, but I have been told by reliable sources that the pipes are big enough to cover the 0630 head ports. You keep the precats and the O2 sensors bolt in fine.
 
Now I'm confused. I thought you said the 2000+ headers didn't work well with the ports on the 0630 head - isn't that what the tracings you posted on the first page of the thread showed? I'm probably missing something here.
 
The ehxaust may fit, but the ports won't line up with teh manifold very well and you will only have about 1/8" for the manifold to seal on the lower part of the port. The exhaust will be hitting a brick wall on the way out. After market headers for the 2000+ should alleviate this problem as their tubes are larger.
That is what I said earlier. The stock manifold won't line up well. The after market header should work.

Header is different from manifold as is stock from after market.
 
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