318 plenum reinforcement kit

Disclaimer: Links on this page pointing to Amazon, eBay and other sites may include affiliate code. If you click them and make a purchase, we may earn a small commission.

lilfroger

Senior Member
Joined
Aug 29, 2010
Posts
1,224
Reaction score
7
Ram Year
2006
Engine
5.9 CTD
Install Vehicle: 99 Dodge Ram 1500 318 **same engine used in Dakota's, Ram vans, Durango, Grand Cherokee**
Reason for install: vehicle was loosing oil but no visible oil leak was found, vehicle had jumpy idle, vehicle had sluggish throttle response
Dodge TSB 09-05-00 was issues for this problem; but they just install the same plenum intake plate so it will happen again.
Kit ordered: Hughes Engine V8 INTAKE GASKET HUG 3226 and Hughes Engine PLENUM REINFORCEMENT KIT HUG 7712 from Hughes Engines Kit comes with new intake bolts & bolts for plate.
Other Parts purchased for install: 185 thermostat and coolant intake by-pass hose (hose tends to leak if re-installed so installing a fresh one is just better)
Tools needed: full set of metric and standard wrenches and sockets; make sure you have extensions (you'll need em), INCH POUND TORQUE WRENCH, blue lock tight, black RTV

The 318 before we started:
DSCN4189.jpg

Disconnect battery & remove coolant overflow bottle
Remove ail filter, plenum and intake tube
DSCN4193.jpg
Disconnect throttle cable bracket at throttle body
Remove four (4) fan blade bolts push fan back towards water pump. This is to gain clearance for fan shroud removal.
Remove windshield washer fluid bottle from shroud. Remember there are two (2) table inside shroud that need to be released to pull bottle upwards.
DSCN4195.jpg
Slide fan shroud upwards then out. This is to give room to stand in engine compartment to make to easier.
DSCN4197.jpg
Remove belt
Remove alternator leads and alternator
Remove ac support, brackets and bolts
Remove IAC, Map, and throttle position sensor connectors
Remove throttle body, gasket, and four (4) bolts
DSCN4203a.jpg
Remove AC compressor connectors (2) Remove AC compressor and swing to passenger side fender (4 bolts)
DSCN4204.jpg
Remove cross bracket (support for ac lines & air box)
DSCN4205a.jpg
Remove Injector connectors (8)
DSCN4207.jpg
Remove heater core coolant supply hose
DSCN4209.jpg
Drain coolant: drain plug turns 1/4 turn clockwise then turn and pull out
DSCN4210.jpg
Bleed fuel rail pressure with shrader valve then remove fuel rail with Injectors intact
DSCN4213.jpg
DSCN4214.jpg
(tie the rail out of the way)
DSCN4216.jpg
Remove all wiring and associated line, plug wires and upper radiator hose
Remove coolant bypass hose (a new one will be installed on re-assembly)
DSCN4217.jpg
Plug injector holes to stop debris from getting into cylinders
DSCN4222.jpg
**Clean all dirt & debris from crevices: if not it will fall into engine**
Remove all intake bolts & remove intake
DSCN4225.jpg
Place rag or towel on top of valley to prevent gasket debris from falling into valley. Remove all old gasket material.
DSCN4226.jpg
Place intake on clean surface
DSCN4230.jpg
-notice the oil vapor stains from vacuum leak in intake
DSCN4231.jpg
Remove fifteen (15) bolts and lower plate
DSCN4232.jpg
-note the oil that was pooling inside the intake
DSCN4233.jpg
Clean intake toughly inside and out: don't use a wookie or scotch-bright: you will get high/low spots and intake will leak
DSCN4234.jpg
DSCN4236.jpg
Install new intake plate per instructions in kit. **Note torque specks are INCH pounds not foot pounds**
torque to 48 inch pounds
torque to 84 inch pounds
torque to 84 inch pounds
DSCN4239.jpg
Install new intake gaskets: use black RTV on lower corners where they cross
DSCN4241.jpg
Reinstall intake
torque bolts 1 through 4 to 72 inch pounds 12 inch pounds at a time
torque bolts 5 through 12 to 72 inch pounds 12 inch pounds at a time
torque all bolts to 72 inch pounds
torque all bolts in sequence to 12 foot pounds
torque all bolts in sequence to 12 foot pounds
DSCN4220a.jpg
Once fully torqued begin re-installing all removed components
Add coolant and check oil levels
 
OP
OP
L

lilfroger

Senior Member
Joined
Aug 29, 2010
Posts
1,224
Reaction score
7
Ram Year
2006
Engine
5.9 CTD
Thank you...really common issue w/ ever 318. Dodge's fix was to install the same plate and retard the timing smiley_emoticons_ahhh.gif

The Hughes kit is top freaking notch. Their customer service is great. Buddy of mine got a plate that had at some point taken a tumble and got a few good scratches in it. He called them and they sent him a replacement out that night. He still had the parts by the weekend to do the install.

Any company that makes a great product and has great service is top notch in my book.
 

Bigtman07

Registered User
Joined
Jun 28, 2010
Posts
9,329
Reaction score
287
Location
Piqua, Ohio
Ram Year
2000
Engine
Cummins 5.9
Awesome Writeup! Good deal. Love seein this DIY Section Grow. I have done the plate replacement myself.
 

AWE Daniel

Banned
Joined
Jun 29, 2010
Posts
3,750
Reaction score
0
Ram Year
2004
Engine
Hemi 5.7
Is it really worth your time to register all these accounts just to see them get banned with 1 click? Go be a **** somewhere else.
 
Last edited:

Mega-Hemi

US AIR FORCE '08-'18
Military
Joined
Jun 28, 2010
Posts
1,286
Reaction score
360
Location
Back in New York!
Ram Year
2020
Engine
6.7 Cummins
This is a very common problem but it's not only the 318/5.2, this write up can also be used for the 360/5.9 which has the exact same plenum gasket problem. Nice write-up.
 

Da Bear

Junior Member
Joined
Sep 29, 2011
Posts
1
Reaction score
0
Location
Fort Walton Beach FL.
Ram Year
1999 Larami SLT 4x4
Engine
5.2
palm 041.jpglilfroger- just did my hughes plenum pan swap using your post. Turned out great. pics were a life saver, most taxing part was cleaning up the surfaces for re-install. Have b een getting 9 mpg since I got the truck from my father in law back in 05, figured it was just a gas hog. Started getting the knock during acceleration and looked into it. All the symptoms pointed to a blown gasket. Thanks for your help. will let you know my gains.
 
Last edited:

bigTRuckdriver

Junior Member
Joined
Oct 3, 2011
Posts
2
Reaction score
0
Location
fort worth, tx
Ram Year
2002
Engine
5.9 l
how did it turn out

i saw you were getting 9 mpg before the install, did you mpg increase after the install? i think this may be wrong with my truck, im getting about 9 mpg currently
 

txbass06

Supporting Member
Joined
Oct 27, 2010
Posts
4,129
Reaction score
54
Location
NE Texas
Ram Year
1996
Engine
5.9 Magnum
i saw you were getting 9 mpg before the install, did you mpg increase after the install? i think this may be wrong with my truck, im getting about 9 mpg currently

Pull the intake hose off the throttle body and crack the blades open. If you see any oil or residue in the intake at all, your plenum gasket is leaking


Sent from my iPhone 4 using Tapatalk
 

ramthis9501

Senior Member
Joined
Jul 25, 2010
Posts
2,939
Reaction score
31
Location
Oklahoma
Ram Year
2001
Engine
5.2 V8
Did this myself a couple months ago and it's amazing the difference it made in performance. No more sluggish running and alot better throttle response. Maybe got 1-2 more mpgs
 

V-10 RAM

Senior Member
Joined
Oct 20, 2011
Posts
185
Reaction score
1
Location
Lee Vining CA
Ram Year
1999
Engine
v-10
Well checked my Jeep 5.9 & now I know why I'm pinging, & having CEL on converter running too cold, why my mileage has dropped into the 15 range from the mid 17 area. The interesting thing is my oil usage is very little. But the intake has a lot of oil residue.
So that has to be fixed pretty soon. I haven't been driving it much because I have four vehicles.
 

V-10 RAM

Senior Member
Joined
Oct 20, 2011
Posts
185
Reaction score
1
Location
Lee Vining CA
Ram Year
1999
Engine
v-10
Thanks for the links. Yes a bit cheaper. With shipping & gaskets it comes to $94.33 which it's a big savings but plenty to interest me.
Thanks Again
 

Hylander

Member
Joined
Nov 13, 2011
Posts
52
Reaction score
11
Location
Commiefornia
Ram Year
2007
Engine
Hemi 5.7
Thanks for the write up :)
I have a 94 1500 5.9, just replaced my T-Stat today.
I have residue in my intake, so looks like I need to do this repair.

Question:
How long can I continue to drive in this condition ?
Truck Runs fine, passed smog and I get 10-11 mpg in town and 15 hwy.
This is with 33" tires and 4.10 gears.
I probably can't afford to do the repair until after Christmas.
 

ktm1217

Senior Member
Joined
Mar 19, 2011
Posts
365
Reaction score
66
Location
White Mills, PA
Ram Year
1999
Engine
5.2L 318ci Magnum
How long does this usually take to do? Im prob gonna have to do it on my Ram in the near future..
 

ks2007

Junior Member
Joined
Nov 12, 2011
Posts
17
Reaction score
0
Location
Tennessee
Ram Year
1997
Engine
5.2L Magnum
also depends how much you have to clean. I'm still cleaning mine 2 days later. I'm just replacing everything I can now. Don't wait too long or this will happen. I didn't have any trouble until last week and I wish I knew to check it sooner.
 

Attachments

  • 373947_320972477916717_100000119020275_1475180_255613302_n.jpg
    373947_320972477916717_100000119020275_1475180_255613302_n.jpg
    96.5 KB · Views: 448
  • 308867_320971974583434_100000119020275_1475178_285476109_n.jpg
    308867_320971974583434_100000119020275_1475178_285476109_n.jpg
    93.5 KB · Views: 671
Last edited:
Top