Five problems related to manifold/header/muffler/tail pipe have been reported for the 1999 Honda Passport. The most recently reported issues are listed below.
Well in July 2012 I was driving my Honda when I heard noise (sounded like a muffler leak) hit a small dip in the road then a pop and then loud noise coming from engine. I took it immediately to the repair shop and they said the catalytic converter had blown a hole in it self. They said they had never seen anything like it. Well here it is January 2013 and just last week the other side (my car has two converters, lucky me) did the exact same thing. This is just the weirdest thing ever and so very expensive to fix. Is this normal? I don't think so and no one can give me an explanation on why this is happening. I need some help please.
After a year of owning this vehicle, started stalling out even while driving (automatic trans). Check engine light came on, and was told by dealer that the manifold gasket needs to be replaced. Wants over $600 to do so. I can't afford it yet, so I'm dealing with the stalling until I can pay to have it fixed, but I'm wary of it because I've researched the problem and found the defect is repetitive in this vehicle.
Abs system pump was continuously running with keys removed from ignition. Pump was extremely hot to the touch and had to be disabled by removing the abs system fuse. Abs system failure light came on and is still on. No problems with brake system prior to this failure. Car was serviced for exhaust pipe replacement 1 day prior to abs system failure.
Fuel system problem: fuel gauge frequently has begun to drop to a reading of zero when the car is not moving but running. The reserve light will blink and the fuel gauge will not show any fuel reading until the car begins moving again. It can take several minutes before a correct reading is shown. Intake manifold system failure: date and mileage is approximated, will locate records with exact date and mileage. Both left and right side intake manifold gaskets were reported as "cracked" by the dealer and replaced at a charge of $400 (not under warranty). Engine idled roughly and stalled prior to repair. TSB from Honda is available.
Intake manifold gasket leaked causing engine to shut off while driving, especially when braking. Intake manifold gaskets were replaced by dealership.