TSB # 09-06-99
Date: . Sep. 10, 1999
models: 1994-99 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
NOTE: THIS BULLETIN APPLIES TO VEHICLE EQUIPPED WITH A 3.9L, 5.2L. OR 5.9L GASOLINE ENGINE.
Discussion:
This bulletin involves the replacement of the engine intake manifold plenum pan gasket.
The test procedure and the parts list for the different engines follows in the TSB. Both the above are "...reimbursable within the
warranty.", meaning you will have to pay for it if you are past the 3/36. Fight that out.
Symptoms:
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 noise
during acceleration and/or a high amount of engine oil consumption.
The intake manifold plenum pan gasket has been revised to address this condition.
Diagnosis:
If the intake manifold plenum pan gasket is leaking, a vacuum source will be created in the engine. Any engine blow-by and
outside filtered air will be drawn past the leaking pan gasket and into the intake manifold. In most cases, an engine at idle will
create the highest vacuum and lowest amount of engine blow-by.
1 . Remove the positive crankcase ventilation (PCV) valve at the cylinder head valve cover. Clean the PCV valve grommet in
the valve cover of any oil residue.
2. Remove the breather hose from the air cleaner assembly and seal off the breather hose going to the cylinder head valve
cover.
3. Attach a gauge that reads both pressure and vacuum (+/- 10 in. Hg.).
4. Start the engine and observe gauge readings. If the intake manifold pan gasket is leaking, then a vacuum reading greater
than -2 in. Hg. will be observed. If no internal leaks are present, then the gauge will read near zero to slightly positive pressure.
If a the pan gasket is leaking then perform the Repair Procedure.
Parts:
For the 5.2L / 5.9L:
1 04897383AC Package, Intake Manifold Gasket
1 05017208AA Gasket, Intake Manifold Plenum Pan
15 06034583 Screw, Intake Manifold Plenum Pan
1 53030541 Gasket, Throttle Body
For the 3.9L:
1 04897382AC Package, Intake Manifold Gasket
1 05017207AA Gasket, Intake Manifold Plenum Pan
14 06034583 Screw, Intake Manifold Plenum Pan
1 53030541 Gasket, Throttle Body
repair:
1. Refer to the appropriate year Service Manual, Section 9: ENGINE for removal and installation instructions.
NOTE: CLEAN ALL OIL FROM THE INTERIOR SURFACES OF THE PLENUM PAN AND PLENUM CHAMBER.
NOTE: THE PROPER TORQUE AND TIGHTENING SEQUENCE MUST BE FOLLOWED WHEN TIGHTENING
BOTH THE PLENUM PAN SCREWS AND THE INTAKE MANIFOLD SCREWS.
Notes:
POLICY. Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 09-50-15-91 ......................................................... 3.0 Hrs.
09-50-15-60 ......................................................... 0.2
09-50-15-62 ......................................................... 0.8
09-50-15-65 ......................................................... 0.2
FAILURE CODE: P8 - New Part
Note: Both the above engine problems are "...reimbursable within the warranty.", meaning you will have to pay for it if you are
past the 3/36. Fight that out.
***************************************
TSB 18-24-98
Light Spark Knock Timing Retard Feature
Date: Jul. 31, 1998
Models: 1996 - 1997 (BR) Ram Truck
1996 -1997 (AB) Ram Van
1996 -1997 (AN) Dakota
1996 - 1997 (BR) Ram Truck
1996 - 1997 (XJ) Cherokee
1996 - 1997 (ZJ) Grand Cherokee
1996 - 1997 (ZG) Grand Cherokee (international Markets)
NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 2.6L, 4.OL, 3.9L, 5.2L AND 5.9L
LIGHT DUTY GASOLINE ENGINES.
Symptom/Condition:
Some vehicles may exhibit light spark knock with a warm engine under load.
Discussion:
Determine when the customer exhibits this condition and verify it by driving the vehicle in similar conditions. If the vehicle
exhibits light spark knock with a warm engine under load perform the flash update procedure. Once the flash procedure is
completed, spark advance/retard may be adjusted.
Diagnosis:
Select DRB III stand alone, current model year diagnostics, engine, and miscellaneous. When in miscellaneous, spark advance
will be available. Use the arrow keys to retard timing in 2 degree increments to a maximum of -4deg'. When the DRB lll screen
reads 0 the vehicle will be set at maximum advance and when at -4 it will be set at maximum retard.
NOTE: THE IGNITION KEY MUST BE CYCLED FOR THE CHANGES TO TAKE EFFECT.
After performing the spark advance/retard feature, drive the vehicle to verify that the light spark knock is gone.
This feature will not compensate for heavy spark knock conditions. If heavy knock is experienced, further diagnosis and testing
will be required.
Repair:
This Procedure involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new
software.
NOTE: The MDS and DRB III are required to perform this repair and the system must be operating with release
21 or higher AND TIL CD RELEASE 1165 or higher must be installed. The DRB III must be operating at release
25.5 or higher.
1 . Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up.
2. there was no 2 in this set of instructions!
3. Use the arrow keys and select #2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen.
4. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU.
5. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU.
6. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MI)S & DRBIII on the
MDS, then press NEXT MENU.
7. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the
PCM.
8. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then
press NEXT MENU to begin programming.
If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be
displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has
already been updated, then another condition exists that will require further diagnosis and repair.
9. The MDS and DRB lllo will prompt for any operator action needed during the remainder of the programming process.
The following steps are required by law:
10. Type or print necessary info on the "Authorized Software Update"
label (Fig 1) and attach it to the ECM. Cover the label with clear tape.
11. Type or print the following information on the Authorized Modification Label and attach the label near the VECI label
(Fig 2).
notes:
Policy: Reimbursable within the provisions of the warranty
Time Allowance:
Labor Operation No: 08-19-41-96 . . . . . . . . .0.5 Hrs.
Failure Code: FM - Flash Module
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