318 Plenum Reinforcement kit install

[DOF Info]

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 http://www.hughesengines.com/Index/products.php?&partid=27091 Kit comes with new intake bolts & bolts for plate.

**updated part information: Hughes kit is now 7720R and comes with manifold bolts, thermostat, & bypass hoses.**

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:


Disconnect battery & remove coolant overflow bottle
Remove ail filter, plenum and intake tube

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.

Slide fan shroud upwards then out. This is to give room to stand in engine compartment to make to easier.

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

Remove AC compressor connectors (2) Remove AC compressor and swing to passenger side fender (4 bolts)

Remove cross bracket (support for ac lines & air box)

Remove Injector connectors ( 8 )

Remove heater core coolant supply hose

Drain coolant: drain plug turns 1/4 turn clockwise then turn and pull out

Bleed fuel rail pressure with shrader valve then remove fuel rail with Injectors intact


(tie the rail out of the way)

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)

Plug injector holes to stop debris from getting into cylinders

**Clean all dirt & debris from crevices: if not it will fall into engine**
Remove all intake bolts & remove intake

Place rag or towel on top of valley to prevent gasket debris from falling into valley. Remove all old gasket material.

Place intake on clean surface

-notice the oil vapor stains from vacuum leak in intake

Remove fifteen (15) bolts and lower plate

-note the oil that was pooling inside the intake

Clean intake toughly inside and out: don't use a wookie or scotch-bright: you will get high/low spots and intake will leak


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

Install new intake gaskets: use black RTV on lower corners where they cross

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

Once fully torqued begin re-installing all removed components
Add coolant and check oil levels

[i11m10c2]

Impression since install:
Instant increase in throttle response
Truck doesn't stumble at idle
Idle is smoother with less tach jump
Condensation and steam now coming out of exhaust

Still to do:
plugs
wires
cap
rotor
cam shaft sensor
remount crank shaft sensor 4 degrees

[Kilch123]

Wow - pretty big job, but sounds like it solved your problems!

Good Deal!

[noplugs]

Wow - pretty big job, but sounds like it solved your problems!

Good Deal!

No kidding. How long did it take you?

[lilfroger]

Started Friday night and got down to the intake in the removal.  Finished up Saturday by 3ish. 

We get to do it again on a friends 1st gen Dak as soon as he buys the kits.  Should take a good 6 hrs with out all the pictures and know that they know what they are pulling.

[RoaminGnome]

Well it doesnt look fun but it doesnt look hard either 

Thanks for the write up 

[mayfair]

AWESOME write up !!

[JetNoise]

So what exactly is the difference between the Hughes Reinforcement part over the stock part?

I am looking at doing this repair for my truck, but I don't really have the $120 to throw at it, but I am running through almost 3 quarts of oil every 2,000 miles (my service interval) and I think this may be the problem.  There is no other evidence of oil loss.

I will spend the money if I need to, but I don't see any major differences in the pictures except the stock seems to have a ridge that is more apparent than the replacement.

Thank you for the help!

[lilfroger]

The Hughes kit FIXES the problem.  It is an aluminum plate.  The stock piece is still the flimsy junk.  If you don't replace the plate and just do the seal ... it will leak again.  If you replace the seal and plate with the stock one ... it will fail again.

Do it once ... do it right ... do the Hughes plate and never worry about it again.

[96GreenMachine]

when you hold the hughes plate in your hand, compared to the stock one, you'll notice a huge difference between the two. As Jo said, the stock one feels flimsy and weak, not very thick, and i'm sure warps easily. And thats why the gasket always fails. But the Hughes plate is much stronger, and looks like it won't warp or flex the way the stock one does, therefore keeping the gasket from blowing out. I'm not positive on everything i just said, but thats just my understanding of the replacement kit.

[JetNoise]

Okay, I guess I'll see what my next paycheck holds.  My truck is getting higher on my list of "vehicles to fix" so I am trying to get my ducks in a row.