I doubt the manifold has experienced extreme overheating. I looked previously during installation and couldn't see any cracks, but the gasket might be the issue. I don't know how it took me until now to notice the gasket wasn't right. I ordered a new manifold and should have it installed tomorrow. I'll let you know if that fixes the tapping noise

 

This in the yellow circle appears to be a crack

 

It might be the gasket is upside down, that part number fits the 2.0 ,2.2 and 2.4


I don’t see how it can be upside down, but check your work, match it to the head and the exhaust manifold

 

I didn't mean engine overheating; I meant like raw fuel in the exhaust gas igniting (which would likely melt the cat).

 

Oh okay, that makes sense. I pulled the manifold off, and I didn't see any noticeable cracks. I also shined a light inside to see if any cracks were visible, but I didn't see anything. It also looks like the manifold gasket may have worked. I think the extra portion of the gasket may be possibly making the tapping noise?

 

Looks like you can cut away the excess gasket material. Block sand the exhaust manifold surface to make sure it’s flat!

 

Tiny exhaust leaks can sound like tapping. Warpage can cause problems with proper gasket seating. Double gaskets is an old trick that might work or might cause later leaks.

With the manifold off, it’s pretty easy to check if the mounting surface is flat.

 

**Deleted**

 

In post #231

 

What’s yer point? He also said he took off the old one and couldn’t detect a leak. He should want to at least try to detect a problem with the old one if not return a possibly unneeded new one.