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Dodge Magnum V8 Intake Plenum Pan Gasket Replacement

PS: Sorry for the silent film. After all the work, I forgot to add music. If your Dodge Ram, Dakota, Durango, or Jeep Grand Cherokee (ZJ) with the Magnum 3.9L V6, 5.2L V8, or 5.9L V8 has been pinging during acceleration or under engine load, and using/consuming oil, then more than likely your Intake Plenum Pan Gasket has blown out and is allowing the engine's vacuum to pull oil from the valley (where the camshaft/pushrods are) into the engine, burning it and causing ping/spark knock. The plenum being one piece, instead of a separate upper and lower intake manifold, requires there to be an opening on the bottom of the plenum during casting since it's such a large piece of aluminum. The solution is to cover it with a pan, as such. The pan is made of very thin aluminum and over time it warps from heat, allowing the gasket to blow out. You can replace the gasket but since the pan is warped, it will only blow out the gasket again and since it's so much work, it's not fun to do it several times. Hughes Engines has a replacement pan that is much, much thicker and is the solution to the warping. It will not warp and the gasket will not blow out again. This is the kit that I used in the video/slide show. It was cold out when I did this a few months ago so I didn't take any video, just pictures. Sorry the video is silent. The kit for the 5.2/5.9 V8's can be found here: http://www.hughesengines.com/Index/products.php?partid=22220 and the kit for the 3.9 V6 can be found here: http://www.hughesengines.com/Index/products.php?partid=22078. By the way, I'm not endorsed or sponsered by Hughes engines, I just highly recommend the kit if you're going to put in the work to replace the gasket. If you have any other questions about the procedure or any other repairs or questions about your Dodge, Chrysler, Jeep/ Mopar product, just send me a message or leave me a comment. This applies to all '93-03 Dodge Ram, Ram Vans, Dakota, Durango, Jeep Grand Cherokee with the 3.9L V6 (239), 5.2L V8 (318), 5.9L V8 (360). As always, disconnect the battery, and be safe and careful with yourself and everything under the hood during this repair. Thanks for watching! Comment, Rate, and Subscribe!


 


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How to tell if your plenum pan gasket is blown
This is an amateur demonstration of the Chrysler-recommended diagnostic test to see whether the Dodge Ram/Durango/Grand Cherokee plenum pan gasket has failed, as described in TSB 09-05-00. Issues of test sensitivity and specificity are raised. A common flaw seen in the Dodge Ram Magnum V8 engine (1994- approx 2003) is a leaking plenum pan gasket. The gasket is said to be prone to failure because the pan is made of steel, and the intake manifold is aluminum. With the different coefficients of expansion between these two metals, and the marked thermal change this area is subjected to, gasket failure is quite common, leading to an internal vacuum leak and oil contamination of the intake manifold. Failure of this gasket may lead to oil consumption, poor gas mileage, pinging under load, and rough idle. This is a demonstration of amateur effort, published in good faith but with no guarantees as to safety or accuracy. Auto repair is intrinsically dangerous and misadventures are to be anticipated and planned for. Do not try this at home without professional advice! Any misadventure you encounter if you should decide to try and repair your vehicle is your responsibility. Thunderclap sound used under Creative Commons 3.0 license, done by RHumphries at http://freesound.org/people/RHumphries/





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How To Find A Vacuum Leak - EricTheCarGuy
Vacuum leaks are one of the biggest causes of engine performance problems. This video is pretty straight forward in it's approach to finding a vacuum leak. On thing I might mention is that not all vacuum leaks are at the engine. Some HVAC systems run on engine vacuum and can cause a leak under the dash in some cases. I've even seen vacuum operated door locks. Just be sure to be careful spraying flammable stuff on a hot engine, you don't want to take one problem and make it a whole lot worse. You can also use a spray bottle with water to do this same test. It may not be as effective, but you don't have to worry about spraying a flammable substance on a hot engine. For more information on diagnosing engine performance issues, check out this article I wrote. http://www.ericthecarguy.com/faq/solving-automotive-performance-issues The best place for answers to your automotive questions: http://www.ericthecarguy.com Facebook: https://www.facebook.com/EricTheCarGuy?fref=ts Twitter: https://twitter.com/EricTheCarGuy Google+: https://plus.google.com/100195180196698058780/posts Information on Premium Membership: https://www.ericthecarguy.com/premium-content-streaming-etcg-content Stay Dirty ETCG Due to factors beyond the control of EricTheCarGuy, it cannot guarantee against unauthorized modifications of this information, or improper use of this information.  EricTheCarGuy assumes no liability for property damage or injury incurred as a result of any of the information contained in this video. EricTheCarGuy recommends safe practices when working with power tools, automotive lifts, lifting tools, jack stands, electrical equipment, blunt instruments, chemicals, lubricants, or any other tools or equipment seen or implied in this video.  Due to factors beyond the control of EricTheCarGuy, no information contained in this video shall create any express or implied warranty or guarantee of any particular result.  Any injury, damage or loss that may result from improper use of these tools, equipment, or the information contained in this video is the sole responsibility of the user and not EricTheCarGuy.





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5.2 ZJ Hughes Air Gap Intake & Big Gulp TB Dual Exhaust Cam
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