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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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98 RAM 1500 Intake Plenum Repair 5.9
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How To Find A Vacuum Leak - EricTheCarGuy
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94 Dodge Ram 318 5.2 - Pictured Progression Through Time
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