This procedure removes and replaces the cylinder head gasket on a 2014 Ram 2500 with 6.7L Cummins diesel engine, including removal of intake/exhaust manifolds, valve cover, and cylinder head components.

Warnings

Tools required

Parts

• Cylinder head gasket × 1 — Use OEM Mopar specification
• Valve cover gasket × 1 — Use OEM Mopar specification
• Intake manifold gasket set × 1 — Use OEM Mopar specification
• Exhaust manifold gasket × 1 — Use OEM Mopar specification
• Cylinder head bolt set × 1 — Use OEM Mopar specification - torque-to-yield bolts
• Injector return line O-rings × 6 — Use OEM Mopar specification
• Injector sealing washers × 6 — Use OEM Mopar specification
• Turbocharger mounting gasket × 1 — Use OEM Mopar specification
• Coolant × 1 — Mopar OAT Purple Coolant

Fluids

• Mopar OAT Coolant (Purple) — 18 qt
• Mopar 5W-20 Synthetic Blend Engine Oil — 13 qt

Preparation

1. Disconnect both battery cables, negative first
2. Drain cooling system completely at engine block and radiator drain plugs
3. Drain engine oil and replace oil filter
4. Remove engine cover and air intake system
5. Remove intercooler and charge air piping
6. Relieve fuel system pressure using scan tool or manual procedure
7. Label and photograph all electrical connections, fuel lines, and vacuum hoses before removal
8. Support engine weight with hoist or overhead support fixture

Procedure

1. 1

   Remove valve cover and accessories
   Disconnect all electrical connectors on valve cover including injector harness. Remove fuel return lines from injectors. Unbolt and remove valve cover. Remove rocker lever assembly by loosening in reverse of tightening sequence.
2. 2

   Remove intake manifold
   Disconnect throttle linkage, EGR system connections, and all intake manifold sensors. Remove intake grid heater connections. Unbolt intake manifold in reverse sequence and remove complete assembly. Inspect and clean all sealing surfaces.
   Torque spec

   Intake Manifold Bolts25 Nm (18 lb-ft)
3. 3

   Remove exhaust manifold and turbocharger
   Disconnect exhaust downpipe from turbocharger. Remove turbocharger oil supply and drain lines. Unbolt turbocharger from exhaust manifold (if separating). Remove exhaust manifold mounting nuts in reverse sequence. Carefully remove manifold and turbocharger assembly.
   ⚠Exhaust studs are prone to breaking on high-mileage engines. Apply penetrating oil 24 hours before removal if possible.
   Torque spec

   Exhaust Manifold Nuts25 Nm (18 lb-ft)
4. 4

   Remove fuel injectors
   Remove high-pressure fuel lines from each injector using proper flare nut wrenches. Cap all open fuel lines immediately. Remove injector hold-down bolts and carefully extract each injector using appropriate puller if necessary. Remove and discard injector sealing washers and O-rings. Cover injector bores with clean shop towels.
   ⚠️Diesel fuel injectors operate at extreme pressure. Ensure fuel system is completely depressurized before removal.
5. 5

   Remove pushrods and crossheads
   With rocker assembly removed, extract each pushrod and mark position for reinstallation in same location. Remove crosshead guide assemblies. Keep all components organized in order. Inspect pushrods for wear, bending, or damage.
   ℹ️Pushrods must be reinstalled in their original positions. Use a numbered organizer or label each component.
6. 6

   Remove cylinder head bolts
   Using proper sequence (reverse of tightening), loosen all cylinder head bolts gradually in multiple passes. Remove all cylinder head bolts completely and inspect threads for damage. Discard all old head bolts - they cannot be reused.
   ⚠Head bolts are torque-to-yield design and must be replaced. Do not attempt to reuse old bolts.
   Torque spec

   Cylinder Head Bolts - Step 140 Nm (30 lb-ft)
7. 7

   Remove cylinder head
   Attach lifting fixture to cylinder head using appropriate bolt holes. Carefully break head loose from block using plastic mallet if necessary - do not pry between head and block surfaces. Lift cylinder head straight up and away from engine. Place on clean, padded work surface with combustion chambers facing up.
   ⚠️Cylinder head weighs approximately 150 lbs. Use proper lifting equipment and get assistance. Secure with lifting fixture before removing.
8. 8

   Clean and inspect cylinder head and block surfaces
   Cover cylinder bores with clean shop towels to prevent debris entry. Remove all old gasket material from block deck and cylinder head surfaces using plastic scraper - do not use metal scrapers that can gouge surfaces. Clean all surfaces with solvent and compressed air. Inspect block deck and head surfaces for warpage using precision straight edge and feeler gauge - maximum warpage specification is 0.002 inches. Check for cracks, especially between valve seats and combustion chambers.
   ⚠Do not allow any debris to fall into cylinder bores, oil passages, or coolant passages. Keep all openings covered when not actively working on them.
   ℹ️If cylinder head is warped beyond specification, it must be professionally resurfaced or replaced.
9. 9

   Install new cylinder head gasket and position cylinder head
   Ensure block deck and head surfaces are completely clean and dry. Install new head gasket on block with proper orientation (markings typically face upward). Check that all dowel pins are in place and not damaged. Using lifting fixture, carefully lower cylinder head onto block, aligning with dowel pins. Remove lifting fixture.
   ⚠Head gasket has specific front/rear and top/bottom orientation. Verify correct positioning before installing head.
10. 10

    Install and torque cylinder head bolts
    Install all new cylinder head bolts finger-tight. Following proper tightening sequence: First pass - torque all bolts to 59 lb-ft. Second - back off all bolts one complete turn. Third pass - torque to 77 lb-ft. Fourth pass - rotate each bolt an additional 90 degrees using angle gauge. Follow manufacturer's specified tightening sequence pattern starting from center bolts working outward.
    ⚠Head bolt torque sequence is critical. Follow the four-step procedure exactly as specified: 59 lb-ft, back off one turn, 77 lb-ft, then +90 degrees.
    Torque spec

    Cylinder Head Bolts - Step 140 Nm (30 lb-ft)
11. 11

    Reinstall pushrods and valve train components
    Reinstall crosshead guide assemblies. Install each pushrod in its original location, ensuring proper seating in lifter and crosshead. Install rocker lever assembly and torque camshaft cap bolts in proper sequence.
12. 12

    Reinstall fuel injectors
    Install new sealing washers and O-rings on each injector bore. Lubricate O-rings with clean engine oil. Carefully install each injector, ensuring proper seating. Install hold-down bolts and torque to specification. Reconnect high-pressure fuel lines using new sealing washers. Torque fuel line connections to specification.
    ⚠Always use new injector sealing washers and O-rings. Reusing old seals will cause combustion gas and coolant leaks.
13. 13

    Install exhaust manifold and turbocharger
    Install new exhaust manifold gasket. Position exhaust manifold and turbocharger assembly (or install separately). Install all mounting nuts and torque in proper sequence. Reconnect turbocharger oil supply and drain lines with new gaskets. Connect exhaust downpipe.
    Torque spec

    Exhaust Manifold Nuts25 Nm (18 lb-ft)
14. 14

    Install intake manifold
    Install new intake manifold gaskets ensuring proper orientation. Position intake manifold assembly and install all mounting bolts finger-tight. Torque intake manifold bolts in proper sequence. Reconnect all sensors, EGR connections, throttle linkage, and grid heater.
    Torque spec

    Intake Manifold Bolts25 Nm (18 lb-ft)
15. 15

    Install valve cover and final reassembly
    Install new valve cover gasket. Position valve cover and install all bolts finger-tight. Torque valve cover bolts in proper sequence. Reconnect injector harness and all electrical connections. Install fuel return lines to injectors. Reinstall intercooler, charge air piping, air intake system, and engine cover.

Reassembly

1. Refill cooling system with Mopar OAT Purple coolant to proper level
2. Refill engine with Mopar 5W-20 synthetic blend oil (13 quarts) and new filter
3. Reconnect battery cables, positive first then negative
4. Prime fuel system using scan tool or manual priming procedure before starting
5. Verify all electrical connections, fuel lines, and hoses are properly reconnected

Verification

• Start engine and allow to idle - monitor for unusual noises, oil pressure, and coolant temperature
• Check for fuel leaks at all injector connections and high-pressure fuel lines
• Check for coolant leaks at head gasket, intake manifold, and all coolant connections
• Check for oil leaks at valve cover and all oil supply/return lines
• Check for exhaust leaks at manifold and turbocharger connections
• Allow engine to reach operating temperature and verify cooling system operation
• Perform multiple heat cycles and recheck all fluid levels
• Road test vehicle under load and verify proper operation, boost pressure, and no abnormal smoke
• Recheck all torque specifications after first 500 miles of operation

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