![]() I used Autozone for the Inch Pound torque wrench. ![]() Some auto parts stores loan tools for a deposit. Expansion and contraction of aluminum may cause the tighter bolts to snap after you’ve put them in and started driving. The torque settings are pretty low you may be tempted to go harder, don’t. Make sure you get an Inch Pound Torque Wrench for the plenum a foot lb one will snap your new bolts, (I know), and a foot Lb one for the final torqueing of the intake bolts to the block. I guess they assume you are able to figure things out if you’re able to tackle a Plenum gasket. They link these instructions which leaves a LOT unsaid. You get new plenum bolts and all the gaskets with the kit and new intake bolts are about $26 bucks. It explains there why it goes bad and I used the Hughes Engines kit since it eliminates the dissimilar metal problem and they give free tech help on the phone to customers. (I don’t know about all the links on that page but the site is generally good.) Truck feels like it was castrated (loss of power) ![]() Heavy spark knock under load (sounds like a can of marbles when you have your foot in it)ģ. Be careful of that stud holding the fuel rail, driver side closest to the firewall I dropped mine and had to go to the junk yard as it is a discontinued part.ĭodge 3.9, 5.2, 5.9 Barrel Intake Manifold plenum issue and TSB 09-07-97Ģ. NOTE- For some reason Dodge used both metric and SAE sizes on this truck you’ll need a full set of sockets and open end/box wrenches to do the job. getting a chilton or haynes manual to help guide you and give you torque specs will make the job way easier. They are torque-to-yield bolts and will snap if you try to reuse them making the repair a waist of time and money. The main thing to remember is to NOT reuse the plenum pan bolts. If you dont own a torque wrench, you may have to rent or borrow a torque wrench to properly torque the intake bolts. ![]() it can be done with a basic set of hand tools and a torque wrench. Repairing the lower gasket is not a very hard job to do. you can also check spark plugs (particularly #8 ) for excessive carbon build up. If there is just a little bit of oil residue in the intake, its most likely the pcv valve, not the plenum. if there is pooling oil in the corners of the intake, the gaskets are more than likely bad. The easiest way to diagnose this intake leak is by looking into the intake through the throttle plates with a flashlight. On a scan tool it may look like an average vacuum leak. This problem can sometimes be tricky to diagnose if youre not familiar with this problem because it can act like other problems. Symptoms of this failure include: rough idle, lack of power, oil consumtion, heavy spark knock under load, random/multiple misfires (commonly seen on cylinder 1,3, and 8 ), poor mpg. There are kits that can be bought that use all new bolts, a new gasket, and a thicker aluminum pan. this problem can also lead to clogged cat, cracking heads, and fouling o2 sensors. The 2 most common i hear is A: the bolts holding the lower pan are too long and bottom out before they can put sufficient pressure on the gasket and B: the gasket slowly gets torn apart due to different expanding rates between the pan and the intake (pan is steel, intake is aluminum). I’ve heard a few different reasons for why this happens. when the gasket goes bad, it allows oil from the lifter galley to be sucked up into the intake and burned. this gasket seals between the lower pan and the intake manifold. A common problem with the 3.9, 5.2, and 5.9 chrysler/dodge magnum engines is the lower plenum gasket going bad.
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