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How to Remove Install an Exhaust Manifold in a 1995 Dodge Caravan

The exhaust manifold on a Dodge Caravan is responsible for getting the exhaust gasses created by the engine out of the cylinder head and into the exhaust tubing. The manifold is made of cast iron, which can crack under certain atmospheric conditions, or when cold water is applied to a hot manifold. When that happens, the exhaust will come out of the manifold and not out of the exhaust pipe itself, which will make an annoying noise and potentially cause a loss in horsepower.

Instructions

1

Raise the front end of the Caravan with the jack and place a pair of jack stands underneath the front of the chassis. Unbolt the exhaust from the exhaust manifold using the 3/8-inch ratchet, extension and sockets.

2

Unbolt the EGR tube and crossover pipe from the exhaust using an open-end wrench. Unplug the oxygen sensor connection by hand, then remove the oxygen sensor with the oxygen sensor wrench.

3

Unbolt the heat shield from the exhaust manifold using the 3/8-inch ratchet and socket, then unbolt the manifold from the engine with the ratchet. Pull the manifold off of the engine and out of the engine compartment. Remove the exhaust manifold gasket as well.

4

Scrape the mounting surface on the cylinder head using the gasket scraper. Slide the replacement gasket and manifold onto the engine and bolt it in place from the center of the manifold outward using the 3/8-inch ratchet, extension and sockets. Apply a thin coat of the anti-seize compound to the threads of the oxygen sensor, then install the sensor into the manifold.

5

Reconnect the crossover pipe, EGR tube and exhaust to the manifold with a 3/8-inch ratchet and socket. Then reinstall the heat shield with the ratchet. Lower the van off of the jack and jack stands.