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TSB 09-006-02

5.2L Engine - Crack In Cylinder Wall

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Date: August 12, 2002

Models: 2002 (AB) Ram Van

NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO JANUARY 1, 2002.

Discussion:
Customers may complain of one or more of the following

1.    Fluid low in coolant reservoir.

2.    Coolant smell in the exhaust.

3.    White smoke coming from the tailpipe.

4.    MIL (malfunction indicator light) on.

Technicians may notice one or more ot the following:

5.    Misfire on No. 8 cylinder with the MIL on.

6.    Cracked or broken spark plug in No. 8 cylinder.

The DRB I II can be used to confirm that a misfire on No. 8 cylinder is the cause of the MIL "on" condftion. Following the applicable procedures in the service manual (Publication No. 81-370-0255) a cooling system pressure test should be conducted to determine whether or not the system will hold pressure. It the pressure bloods off, the cylinder head should be removed (Section 9, Engine 5.2L, page 9-83) and checked for a crack in the No. 8 cylinder wall (Fig. 1).

NOTE: IF THE MIL IS NOT "ON" AND/OR THE COOLING SYSTEM PRESSURE TEST MEETS SPECIFICATIONS, IT IS UNLIKELY THIS CONDITION EXISTS AND DIAGNOSTICS TO DETERMINE OTHER CONDITIONS SHOULD BE PERFORMED.

NOTE: IF A BORE SCOPE IS AVAILABLE THE TESTS ABOVE MAY NOT BE NECESSARY. ROTATE, THE ENGINE UNTIL THE PISTON IN NO. 8 CYLINDER IS AT BOTTOM DEAD CENTER AND, USING THE BORE SCOPE, CHECK FOR A CRACK IN THE CYLINDER WALL.

7. If the crack exists, follow current warranty policies and service procedures for repair or replacement.

 

Fig. 1 CRACK LOCATION

1 - TOP OF PISTON (MAY SHOW RUST) 2 - CRACK LOCATION IN NC), 8 CYLINDER WALL

Policy:    Information Only

Note: included on this site because Dodge trucks and vans use a similar engine.

This page was edited on: May 3, 2004