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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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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 responsibility. 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: http://www.ericthecarguy.com/vmanuals/22-vmanual-store/153-2002-dodge-ram-4 7l-engine-replacement-vmanual 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 "http://www.incompetech.com/m/c/royalty-free/index.html?feels[]=Humorous" 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! --- Click below and Stay Dirty Visit me at EricTheCarGuy.com http://ericthecarguy.com/ Visit EricTheCarGuy Forum http://www.ericthecarguy.com/forum/default.aspx Visit my Facebook Page: http://www.facebook.com/EricTheCarGuy --- Be safe, have fun and 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.





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: Engine 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 Mopar Lifters Intake 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 Exhaust Stock Headers 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 to... Magnaflow 3.5" Stainless Steel Tips Ignition 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 SOON!!!) Stock Transmission (180,676 miles and still fine!) 242 T-case (Selec-Trac) out of a 97 GC





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