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!
94-01 Dodge 5.2/5.9 Hughes Performance Plenum fix 1 of 2
Video 1 of 2 My first attempt at this video thing.I usually record these
just for my own use to aid in reassembly when doing repairs.I apologize for
the poor editing and camera angles,as I recorded these with my smartphone .
I hope someone will benefit from this.The repair is installing the Hughes
plenum pan/gasket kit ,you can get this kit from their website .The vehicle
is a 99 Dodge 1500 4x4 5.2 .Thanks for watching.
Part II https://www.youtube.com/watch?v=P6CeusX94SU
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
Thunderclap sound used under Creative Commons 3.0 license, done by
RHumphries at http://freesound.org/people/RHumphries/
2002 Dodge Ram 1500 Engine Swap 4.7L Part 1 - EricTheCarGuy
Link to full version of this video:
Link to part 2: http://www.youtube.com/watch?v=QES-WrAB1NI
Visit me at: http://www.ericthecarguy.com/
This truck has been a challenge for me over the past couple of weeks as you
will seen in the video. The lesson here is do your best to check the
engine out before you install it and even that may not be enough. Be
careful when doing a job like this especially if you are by yourself as you
can get seriously injured if your not careful so work carefully and
methodically and things should work out fine.
The music is from the site
under "Royalty Free Music", it's title is "Merry Go-Distressed", the
producer of the site allows the use of this music as long as credit is
given, hence the credit given here. Thank you!
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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
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injury, damage or loss that may result from improper use of these tools,
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responsibility of the user and not EricTheCarGuy.
5.2 ZJ Hughes Air Gap Intake & Big Gulp TB Dual Exhaust Cam
I finally installed an Air Gap Intake Manifold and Big Gulp Throttle Body.
The Top-end and Mid-range of the power band have improved dramatically. I
am very happy with this purchase.
List of Mods:
5.2 Magnum rebuilt bored .030 over
Comp Cam P/N 20-602-9 (206/210 Duration, 112 LSA, .480" in .512" ex lift)
Crane 1.6 Roller Rockers
Mopar Timing Set
Mopar Valve Springs with .600" shims
Hughes Engines/Edlebrock Air Gap Intake
Hughes Engines Big Gulp Throttle Body
K&N Cold Air Intake with IAT sensor installed on it (Air Gap doesn't have a
spot for it which you're told :D)
K&N Air Filter
2.5" Stainless Steel Piping Welded to the headers leading into...
Magnaflow 2.5" Stainless Steel True Core X-Pipe leading into...
Magnaflow 2.5" Stainless Steel Dual In/Dual Out Muffler leading finally
Magnaflow 3.5" Stainless Steel Tips
MSD Digital 6A Ignition Box
MSD Blaster 2 Coil
MSD 8.5" Super Conductor Wires
OEM Champion Spark Plugs
Stock ECU (due to fuel prices, I do still have the Mopar Performance ECU.
The 5.2 would probably push 300 hp and 360 tq with that on now! WILL TEST
Stock Transmission (180,676 miles and still fine!)
242 T-case (Selec-Trac) out of a 97 GC