OEM 2005 Dodge Grand Caravan Exhaust Manifold

2005 Dodge Grand Caravan Exhaust Manifold Parts and Q&A

• Q: How to Service and Repair the Right Exhaust Manifold on 2005 Dodge Grand Caravan?

  A: The first thing to do when servicing the exhaust manifold is to disconnect the battery negative connection and remove the wiper module. After that, disconnect the spark plug wires and unfasten the bolts holding the crossover pipe to the exhaust manifold. Take out the upstream oxygen sensor, plus the screws securing your heat shield and the upper heat shield. Get the vehicle on a hoist and take away the drive belt shield. Release the support strut bolt for the power steering pump, disconnect the oxygen sensor wire from the exhaust below and remove the connection between the catalytic converter pipe and the exhaust manifold. After you have lowered the vehicle, get rid of the power steering pump support strut's top bolt and only then take out the exhaust manifold bolts attaching it to the cylinder head and remove the parts. Look over the manifold and wipe it clean, removing and discarding the gasket if you find one. Also, clean off any dirt from the manifold's surfaces and those of the cylinder head. Verify that the exhaust manifolds are whole and free from cracks, check the flatness of the cylinder head mounting surface and the exhaust crossover mounting surface with a straightedge and a thickness gauge and make sure the manifold surface is not more than 1.0 mm (0.039 in.) warped. Set the exhaust manifold on top of the cylinder head and tighten the bolts to the center runner (for cylinder # 3) to 2.8 Nm (25 in. lbs.) at first. Use a new gasket to join the crossover pipe with the exhaust manifold, tighten the bolts with 41 Nm (30 ft. lbs.) torque, check for heat or corrosion damage on all fasteners with the crossover pipe and change them with OEM bolts if necessary. Insert the remaining manifold attaching bolts and tighten each to 23 Nm (200 in. lbs.). Attach the support strut for the power steering pump and insert the upper bolt and afterwards apply the heat shield and its attaching screws. Install the sensor on the upstream oxygen port, raise the vehicle and connect the catalytic converter pipes to the exhaust manifold, using a new gasket and tighten the bolts to 37 Nm (27 ft. lbs.). Link the oxygen sensor connector at the downstream side, tighten the support strut's bottom bolt for the power steering pump, attach the splash shield while still accessible, lower the car, insert the wiper module and reconnect the negative cable to the battery.