Picked up my Plenum Plate today

[V-10 RAM]

Picked up my plenum plate today. It is heck when your out in the boondocks sometimes.
Anyway, The plate was as described. I found a few TBSs for the 5.2 & 5.9 I thought some may be interested in. I found these on the Jeep forum I belong to. One of my oil in the Kegger was from the PCV. I haven't finished changing my wires yet. I need spray some cleaner in the intake & see if I'm still getting oil.
Thanks Brian, I gave you 100% on your Ebay feedback.

TSB 18-48-98

Ignition System Cross Fire/Secondary Ignition Wire Induction
Note: this page is for the V8 repair. The V6 repair is on another page.

Visit Geno's Garage
for Truck accessories. ​

[SIZE=+1]Date: December 30, 1998[/SIZE]
[SIZE=+1]Models:[/SIZE] 1994-1999 BR/BE Ram
Note: applies to vehicles with 3.9L, 5.2L and 5.9L engines (gas)
1994 - 1999 (AN) Dakota
1994 - 1999 (BR/BE) Ram Truck
1998 - 1999 (DN) Durango
1995 - 1999 (XJ) Cherokee
1994 - 1999 (ZJ) Grand Cherokee
[SIZE=+1]Symptoms:[/SIZE] some vehicles may exhibit one or more of these symptoms:

• spark knock complaints with vehicle under load
• various single cylinder misfire (1, 3, 7,) ad especially 5 and/or 8
• surge in 4th gear with the Electronically Modulated Converter Clutch (EMCC) engaged (around 45MPH).
• Perceived torque converter EMCC engagement/ disengagement around 45 MPH.

[SIZE=+1]Diagnosis:[/SIZE]
Using the Mopar Diagnostic System (MDS/MDS2) or the Diagnostic Scan Tool (DRB III), verify that all engine/transmission systems are functioning as designed. If other DTC's are present, repair as necessary before proceeding with this bulletin. If no other DTC's are present and the above symptoms have been reported by the customer, perform the repair procedure. NOTE: This rerouting procedure should be performed before any other misfire, surge, or spark knock repairs are attempted.
[SIZE=+1]Parts:[/SIZE]
3 56028186 Clip, single wire
2 06503441 Clip, wire to hose (5.2L, 5.9L)
1 04364375 Convolute, 10 ft roll
[SIZE=+1]Repair:[/SIZE] The repair procedure involves rerouting the coil wires and/or the plug wires to minimize induction effects.
NOTE: IF WIRES MUST CROSS DURING THE REROUTE PROCEDURE, THEY MUST CROSS AT A RIGHT ANGLE.
[SIZE=+1]5.2L and 5.9L ENGINE PROCEDURE[/SIZE]
A - Coil Wire Routing (Fig 1 & Fig 2).

1. Remove coil wire from distributor cap tower terminal.
2. Remove coil wire from the rear five-wire clip, the center three-wire clip, and the front one-wire clip along the lower side of the right valve cover.
3. Install 3 one wire clips along the top and front of the valve cover. Use the valve cover retaining bolt studs (Fig 1).
   • 
4. Route the coil wire starting from the ignition coil and working toward the distributor. Any excess wire should end up at the distributor end.
5. Install the coil wire into the one wire clips. This may be easier to perform while the coil wire is loose from the valve cover and before the one-wire clips are attached to the valve cover studs.
6. Cut the ignition wire convolute into three lengths 8", 4", and 3.25" (203 mm, 101.5 mm, 82.5 mm).
7. Slit and install the three sections of convolute onto the coil wire between the clips. Install the 3.25" section at the front of the right valve cover. Install the 8" and the 4" sections along the top side of the right valve cover. This may be easier to perform while the coil wire is loose from the valve cover and before the one-wire clips are attached to the valve cover studs.
8. Route the distributor end of the coil wire down and behind the intake manifold in front of the oil pressure switch.
   • NOTE: The coil wire must be a minimum of 1" away from any other ignition wires. This may require the coil wire to be routed under the vacuum and/or wire harnesses in the right rear corner of the intake manifold.
   • 
9. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil tower terminal.
10. Use the original piece of coil wire convolute to protect the wire against chafing by components at the rear of the engine.

B - Number 8 Cylinder Plug Wire Routing (Fig 3).

1. Remove the #8 plug wire from the distributor tower terminal.
2. Remove the #8 plug wire from the five-wire clip at the lower rear of the valve cover.
3. Route the #8 plug wire over the rear quarter of the right valve cover (Fig 3).
   • 
4. Reposition the original piece of plug wire convolute to prevent the wire from chafing at the right valve cover and with other engine components.
5. Secure the #8 plug wire and convolute in place with the hose to wire clip. The small end of the clip supports the convolute. The large end of the clip attaches to the heater hose.
   • NOTE: Make sure the #8 plug wire is secure and away from the #4 plug wire. Make certain it will not fall to contact the cylinder head or exhaust components.
6. Install the #8 plug wire into its distributor cap terminal.

C - Number 4 Plug Wire Rerouting (Fig 4 & Fig 5).

1. • 
2. Remove the #4 cylinder plug wire from the distributor cap terminal.
3. At the center of the lower side of the right valve cover is three-wire clip. Keep the #2 and #4 plug wires from crossing each other at this clip. Position the #2 plug wire in the top wire slot and the #4 wire in the bottom wire slot. Leave the middle slot empty (Fig 5).
   • 
   • Keep the plug wires from crossing and chafing each other at the five-wire clip found at the right rear lower side of the valve cover. Position the #4 plug wire in a slot that will space it farthest away from the #8 plug wire (Fig 6). Remove any slack in the #4 plug wire between the three-wire and the five-wire clips.
   • 
   • NOTE: Earlier model five-wire clips look slightly different but the same wiring layout applies.
   • 
4. Route the #4 plug wire behind the transmission dipstick tube and heater hoses.
   • NOTE: Make sure that the #4 plug wire is at least one inch away from the #8 wire.
5. Install the #4 Plug wire to its distributor cap terminal (Fig 7).

D - Number 7 Plug Wire Rerouting (Fig 8 & Fig 9)

1. Verify that the #7 plug wire crosses over the distributor cap and leaves the distributor cap between the #3 and the #6 tower terminals (Fig 8). This is the original wire routing on 1998 and earlier models.
   • 

 

[V-10 RAM]

The other tbs

Here is the other TBS. It would not let me post both of them together to much of an overload on the system I guess.

TSB 09-05-00

Spark knock and oil consumption due to intake manifold pan gasket oil leak.
Visit Geno's Garage
for Truck accessories. Geno's Garage Truck Accessories

Date: Feb.25, 2000

THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-06-99, DATED SEP. 10, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS.

Models: 1994-1999 BR/BE Ram truck V6, V8

1994 -1999 (AB) Ram Van
1994 -1999 (AN) Dakota
1994 -1999 (BR/BE) Ram Truck
1998 - 1999 (DN) Durango
1994 - 1998 (ZJ) Grand Cherokee
1996 - 1998 (ZG) Grand Cherokee

THIS APPLIES ONLY A VEHICLE EQUIPPED WITH 3.9L, 5.2L or 5.9L GAS ENGINE.

Discussion:

This bulletin involves the replacement of the engine intake manifold plenum pan gasket.

Symptom/Condition:
An engine intake manifold plenum pan gasket oil leak may occur on some V-6 and V-8 style engines. The oil leak is internal to the engine so no external oil leakage will be present. Two symptoms of this oil leak condition may be present. The vehicle operator may experience an engine spark knock during acceleration and/or an increase in the amount of engine oil consumed by the engine.

Diagnosis:
Make sure Technical Service Bulletin (TSB) 18-48-98 has been performed.

NOTE: IT IS IMPORTANT THAT THE COIL AND SPARK PLUG WIRES ARE ROUTED EXACTLY AS SPECIFIED IN TSB 18-48-98 TO ACHIEVE THE MOST BENEFIT.

Inspect the Positive Crankcase Ventilation (PCV) valve. Shake the PCV valve to verify that the pintle inside of the PCV valve is free. Replace the PVC if the pintle is not free.

If the intake manifold plenum pan gasket is leaking, an additional vacuum source will be created inside of the engine at the location of the pan gasket leakage.- Engine combustion blow-by gases, oil vapor, and air from the crankcase filter/breather may be drawn past the leaking pan gasket and into the intake manifold. In most cases when this condition occurs, an engine at idle will create the highest vacuum and lowest amount of engine blow-by.

1. Allow the engine to reach normal operating temperature.

2. Stop the engine.

3. Disconnect the breather hose from the air cleaner.

4. Attach a vacuum I pressure gauge to the end of the breather hose (Figure 1).


1 - VACUUM / PRESSURE GAUGE
2 - BREATHER HOSE
3 - VALVE COVER BREATHER HOSE PORT

5. Disconnect the PCV valve hose from the intake manifold.

6. Seal off the intake manifold PCV valve hose port opening.

7. Seal off the open end of the PCV valve hose (Figure 2).

NOTE: DURING THIS DIAGNOSIS, IT WOULD BE NORMAL FOR THE ENGINE TO DEVELOP PRESSURE WITHIN THE ENGINE CRANKCASE. THIS IS DUE TO -THE NORMAL PROCESS OF. EXHAUST BLOW-BY- GASES- LEAKING PAST THE ENGINE PISTON RINGS AND ACCUMULATING IN THE ENGINE CRANKCASE. DO NOT ALLOW MORE THAN 3 PSI (20.7 kPa) OF PRESSURE TO BUILD WITHIN THE ENGINE WHEN PERFORMING THE FOLLOWING DIAGNOSTIC PROCEDURE.

8. Start the warmed engine and observe the vacuum gauge.

9. Allow the engine to idle for approximately 30 seconds. Do not allow more than 3psi (20.7 kPa) of pressure to develop in the engine crankcase.

10. If the attached vacuum I pressure gauge does not indicate that a vacuum is present in the engine crankcase, then the intake manifold plenum pan gasket is good and no further internal engine vacuum leak diagnosis is required.

11. If an internal vacuum leak is present then perform the Repair Procedure.

Parts Required*:

For the 5.2L / 5.9L:
1 04897383AC Package, Intake Manifold Flange Gasket and Bolts
1 05017208AA Gasket, Intake Manifold Plenum Pan
15 06034583 Bolt, Intake Manifold Plenum Pan
1 53030541 Gasket, Throttle Body'
2(AR) 04318001 Conditioner, Combustion Chamber

For the 3.9L:
1 04897382AC Package, Intake Manifold Flange Gasket and Bolts
1 05017207AA Gasket, Intake Manifold Plenum Pan
14 06034583 Bolt, Intake Manifold Plenum Pan
1 53030541 Gasket, Throttle Body
2(AR) 04318001 Conditioner, Combustion Chamber

*NOTE: the part numbers are continually being revised. Use the most recent part numbers from the dealership computer if you perform this repair yourself.

Repair Procedure:
1. Refer to the appropriate year Service Manual, Section 9: ENGINE for removal and installation instructions.

NOTE: CLEAN ALL OIL RESIDUE FROM THE INTERIOR SURFACES OF THE PLENUM PAN AND THE INTAKE MANIFOLD PLENUM CHAMBER.

NOTE: THE PROPER BOLT TORQUE AND TIGHTENING SEQUENCE IS CRITICAL AND MUST BE FOLLOWED WHEN TIGHTENING BOTH THE PLENUM PAN BOLTS AND THE INTAKE MANIFOLD FLANGE BOLTS.

3.9L Bolt Tightening Sequence and Torque Procedure:

3.9L Plenum Pan Bolt Torque Procedure
STEP WHICH BOLT TORQUE
1 All Bolts 5.4 Nm (48 in. lbs.)
2 All Bolts 9.5 Nm (84 in. lbs.)
3 Check All Bolts 9.5 NM (84 in. lbs.)
3.9L Intake Manifold Flange Bolt Torque Procedure
STEP WHICH BOLT TORQUE
1 1 and 2 1.4 NM (12 in. lbs.)
2 1 and 2 2.7 NM (24 in. lbs.)
3 1 and 2 4.1 NM (36 in. lbs.)
4 1 and 2 5.4 NM (48 in. lbs.)
5 1 and 2 6.7 NM (60 in. lbs.)
6 1 and 2 8.1 NM (72 in. lbs.)
7 3 through 12 8.1 NM (72 in. lbs.)
8 Check All Bolts 8.1 NM (72 in. lbs.)
9 All Bolts 16.3 NM (12 ft. lbs.)
10 Check All Bolts 16.3 NM (12 ft. lbs.)

5.2L/5.9L Bolt Tightening Sequence and Torque Procedure:

5.2L / 5.9L Plenum Pan Bolt Torque Procedure
STEP WHICH BOLT TORQUE
1 All Bolts 5.4 NM (48 in. lbs.)
2 All Bolts 9.5 NM (84 in. lbs.)
3 Check All Bolts 9.5 NM (84 in. lbs.)
5.2L / 5.9L Intake Manifold Flange Bolt Torque Procedure
STEP WHICH BOLT TORQUE
1 1 and 4* 1.4 NM (12 in. lbs.)
2 1 and 4* 2.7 NM (24 in. lbs.)
3 1 and 4* 4.1 NM (36 in. lbs.)
4 1 and 4* 5.4 NM (48 in. lbs.)
5 1 and 4* 6.7 NM (60 in. lbs.)
6 1 and 4* 8.1 NM (72 in. lbs.)
7 5 through 12 8.1 NM (72 in. lbs.)
8 Check All Bolts 8.1 NM (72 in. lbs.)
9 All Bolts 16.3 NM (12 ft. lbs.)
10 Check All Bolts 16.3 NM (12 ft. lbs.)

* The bulletin clearly says to tighten bolts 1 and 4, but this is probably a typo because the service manual says to tighten bolts 1 through 4, and nowhere in the TSB does it say to tighten bolts 2 and 3, which would only be tightened to 12 ft. lbs when you reach step 9.

2. With the engine reassembled, inspect the coil and spark plug wires for proper routing. Refer to TSB 09-48-98 for additional assistance.

3. Start the engine and allow it to warm to normal engine operating temperature.

4. Decarbon the combustion chamber using Mopar Combustion Chamber Conditioner (p/n 04318001) per the instructions.

NOTE: ALLOW THE COMBUSTION CHAMBER CLEANER TO SOAK INSIDE OF THE ENGINE FOR 2 TO 2.5 HOURS. NOTE: A SECOND APPLICATION OF THE COMBUSTION CHAMBER CONDITIONER MAY BE REQUIRED IF THERE WAS A LARGE QUANTITY OF OIL LEAKAGE PAST THE INTAKE PLENUM PAN GASKET.

5. Verify proper engine oil level.

Notes:

Policy: Reimbursable within the provisions of the warranty.

Time Allowance:
Labor Operation No: 09-50-15-91 .................................. 3.0 Hrs.
Optional Equipment:
09-50-15-60 Air Conditioning Equipped (AN/BR-BE/DN/ZJ) ............ 0.2 Hrs.
09-50-15-60 Air Conditioning Equipped (AB) .................................... 0.8 Hrs.
09-50-15-62 Air Injection Pump Equipped (SR/BE) ........................... 0.2 Hrs.
09-50-15-65 Power Steering Pump Equipped (if 5.2L and AN/BR-BE/DN/ZJ) .. 0.2 Hrs.

Failure Code: P8 - New Part

Thanks to Bob Bergevin for supplying this TSB information

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This page was edited on: May 3, 2004