I'm about to do the plenum intake gasket fix and replace the timing chain on my 01 dodge 1500 5.2L 4wd truck. Curious if you have to remove the fuel rail/injectors to remove the intake? I was thinking about removing the intake/throttle body/fuel rail as a complete unit. If the fuel rail has to be removed, anybody have issues with damaged orings on the injectors (fuel leaks).

 

I can only share with you that if I am gonna go as far as to take all of this apart ,I choose to take it all apart clean and inspect everything while it is accessible, the distributor, oil sensor, vac line, electrical connectors .I did have fuel injector o rings that needed replaced and the electric connector were brittle and most were missing the wire clips so it was a benefit to check this all out,believe me not a job you want to do on a regular basis,ND if the crank sensor is bad it's way easier to get to it with the plenum out of the way

 

You can leave the fuel rails and injectors attached to the intake, I have done it several times.

 

Well my fellow warriors,I hath returned from my task of defeating the plenum problem but to no avail.The dreaded plenum has taken on a more sinister and vile cloak that has forced reading of vacuum far too high for the engine to stay running .So it is with a wicked headache and a humbled ego that I have removed the plenum once more to recheck all the repairs and am retracing my attempts but to no avail so far . The vacuum solenoid appears to be leaking so i have summoned the parts masters @ Rock Auto to send the latest components and some new gaskets and tty bolts, then I shall proceed to make the appropriate repair, and If the lords of Mopar be with me, we shall vanquish this latest enemy to a far away part of the galaxy , and return balance once more to our fair planet.For those that have followed know, THE UNIVERSE ABORES A VACUUM.............

 

Have been resurrecting a 95 2500 with the 5.9 magnum. 84 k, flatbed single cab. A farmer had one of his employees run into it with a farm implement, then it went to the barn and has been there from 2010 till 6 months ago. I replaced the water pump, etc, only to have a coolant leak arrive from the plenum, just after I buttoned it up. So today it came apart again. Thankfully I found your posts before putting the thing back together, so first off, thank you all. I then tried both of the old links, Hughes and the other, but they are no good. Is there still someone making the aluminum plenum piece still? And are the Fel-pro bolts ok or do I want to do something different now?

 

There are some folks on Ebay selling the plenum plate, hughes still has it as well, just gotta go digging thru their site.

In all reality though, a GOOD quality gasket, and trimming the bolts for the steel plenum pan is more than adequate to the task. It isn't about dissimilar metals, it's about cheap gaskets, and bolts that were too long.

 

Thank you, on to putting the beast back together.

 

Here are some pictures of my intake. Should I try to clean these channels out before I reassemble? If so, what solvent/cleaner have you guys used effectively? Or do you just leave it alone?

 

Brake, or carb cleaner.... just spray it in there, and if it comes off, fine. If it doesn't, well, that's fine too.

I took the intake I was going to swap in to the machine shop, and had it hot-tanked. But, I had picked up a spare, as I knew that was going to take a while.

 

I hit it with a little both today and neither seemed to faze it. I figured if it was that baked on, it prolly wouldn’t matter if it didn’t come off.
Thanks