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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
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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





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