Mike68, I'm aware that's it's more than month later, but, just in case you check this thread, you definitely want to go back to your dealer and scream bloody murder.

Those covers aren't cosmetic. They play a vital role in protecting the surrounding components from heat. For instance, the pre-Cat O2 sensor has wires that run over a portion of the manifold. Without the cover, those wires are going to fry.

On a separate note, my 97 Honda (120K) threw a P0135 (O2 sensor) CEL, and after some inspection, I found the telltale hairline crack on the manifold. I've arranged for service on Wednesday with what used to be my regular Honda Dealer, but, to be honest, I'm not getting a great feeling about it. When I mentioned the cracked mani the advisor said something like "Under the warranty, we'll only repair what's responsible for throwing the CEL," rather than what I was hoping to hear- "Oh, yeah, a crack manifold- that's a common issue with that year." When I called American Honda, they said the Dealer had to prove that the manifold part broke as a result of a defect rather than wear and tear. With an 11 year 120K car, it's got a LOT of wear and tear. It's an old car, stored outside, so the paint is in pretty bad shape, and although I've been fastidious about maintenance, it's been a solid 5 years since it's seen the inside of a Honda Dealership.

I really don't want to have to do this, but I get the feeling that I might need to call around until I reach a dealer who's aware of this defect. If they're aware of the defect, I might have less of a battle.

If anyone is still reading this thread what do you think? A mountain out of a molehill or better safe than sorry?