Replace a single lifter (cam follower) on the 6.7L Cummins diesel engine, requiring removal of the valve cover, rocker arm assembly, and pushrod to access the lifter bore.

Warnings

Tools required

Parts

• Engine lifter (cam follower) × 1 — Use OEM specification
• Valve cover gasket × 1 — Use OEM specification
• Pushrod (if damaged or worn) × 1 — Inspect before replacement
• Engine oil × 3 — 5W-40 synthetic diesel oil
• Thread sealant (Mopar approved) × 1 — Use OEM specification

Fluids

• Mopar 5W-20 Synthetic Blend — 3 qt

Preparation

1. Park vehicle on level surface, engage parking brake, and chock rear wheels
2. Disconnect both battery negative terminals to prevent accidental starter engagement
3. Allow engine to cool completely (minimum 2 hours after operation)
4. Remove engine cover and intake air ducting for access
5. Position drain pan under engine and drain approximately 3 quarts of engine oil to lower oil level below lifter bores
6. Identify which lifter requires replacement and note cylinder number and valve position (intake or exhaust)
7. Clean valve cover and surrounding area thoroughly to prevent debris entry into engine

Procedure

1. 1

   Remove valve cover
   Disconnect electrical connectors and fuel lines as necessary for clearance. Remove valve cover bolts in reverse of tightening sequence (start from ends, work toward center). Carefully lift valve cover straight up to avoid damaging gasket surfaces. Inspect gasket surfaces for damage or warping.
   Torque spec

   Cover Bolts22 Nm (16 lb-ft)
2. 2

   Rotate engine to position cam lobe
   Using a breaker bar on the crankshaft pulley bolt, rotate the engine clockwise (viewed from front) until the cam lobe for the affected lifter is pointing AWAY from the lifter (base circle position). This is critical - the lobe must not be lifting the lifter. Verify rocker arm has minimum pressure on pushrod by attempting to rotate pushrod by hand.
   ⚠️Attempting to remove rocker arm while cam lobe is lifting will result in sudden spring release and possible injury or component damage.
3. 3

   Remove rocker arm assembly
   Mark rocker arm orientation and position for reassembly. Loosen rocker arm bolts evenly (if shaft-mounted assembly) or remove individual rocker arm bolts. Carefully lift rocker arm away from pushrod. Note: Some 6.7L configurations use individual rocker arms while others use shaft-mounted assemblies. If shaft-mounted, you may need to remove multiple rocker arms to access the shaft bolt securing your specific rocker.
   ⚠Rocker arms are under valve spring pressure. Ensure cam lobe is on base circle before removal.
   Torque spec

   Rocker Arm Bolts30 Nm (22 lb-ft)

   Rocker Arm Shaft Bolts25 Nm (18 lb-ft)
4. 4

   Remove pushrod
   Lift pushrod straight up and out of the engine. Inspect pushrod for wear, scoring, or bending. Roll pushrod on flat surface to check for straightness - any wobble indicates replacement is required. Measure pushrod length and compare to service specifications. Store pushrod in clean area if reusing.
   ⚠A worn or bent pushrod indicates excessive wear or failure mode. Replace if any defects are found.
5. 5

   Remove failed lifter
   Using a lifter removal tool or strong magnet, carefully extract the lifter from its bore. If lifter is stuck, use penetrating oil and allow to soak for 15 minutes. Do NOT use excessive force or pry tools that could damage the lifter bore. Once removed, place lifter aside for inspection. Note orientation of lifter (oil feed holes position).
   ⚠Dropping lifter into engine will require oil pan removal. Work carefully and use magnetic tools.
6. 6

   Inspect lifter bore and camshaft lobe
   Using a mirror and flashlight, thoroughly inspect the camshaft lobe for scoring, pitting, or wear patterns. Inspect lifter bore for scoring or out-of-round condition. Check for metal debris in bore - presence of metal particles indicates additional engine damage. Measure cam lobe lift with dial indicator if wear is suspected. Clean lifter bore with lint-free cloth and inspect oil feed passages for blockage.
   ⚠️Worn cam lobes or damaged lifter bores will destroy new lifter immediately. If cam lobe shows wear, camshaft replacement is required. Do not proceed with lifter replacement only.
7. 7

   Prepare and install new lifter
   Remove new lifter from packaging and submerge in clean engine oil. Pump lifter plunger by hand 15-20 times to prime internal oil passages and collapse air pockets. Coat lifter exterior generously with assembly lube or engine oil. Verify lifter oil feed holes align with bore oil passages. Carefully lower lifter into bore, ensuring it slides freely without binding. Lifter should drop into bore with only light pressure.
   ⚠Air-filled lifters will cause valve train noise and potential damage during initial start-up. Ensure lifter is fully primed with oil.
8. 8

   Install pushrod
   Coat pushrod ends with assembly lube or engine oil. Lower pushrod into position, ensuring it seats properly in the lifter socket and rocker arm cup. Verify pushrod rotates freely by hand - it should spin without binding. If reusing original pushrod, install in exact same location.
   ⚠Improperly seated pushrod will cause rocker arm misalignment and accelerated wear.
9. 9

   Install rocker arm assembly
   Verify cam lobe is still on base circle (pointing away from lifter). Position rocker arm over pushrod and valve stem, ensuring proper alignment. Apply light engine oil to rocker arm contact surfaces. Install and hand-tighten rocker arm bolts. Torque rocker arm bolts to specification with cam lobe pointing away from lifter. If shaft-mounted system, tighten shaft bolts evenly in sequence from center outward.
   ⚠️Tightening rocker arm with cam lobe in lift position will bend pushrod or damage valve train components.
   Torque spec

   Rocker Arm Bolts30 Nm (22 lb-ft)

   Rocker Arm Shaft Bolts25 Nm (18 lb-ft)
10. 10

    Verify valve lash and operation
    Slowly rotate engine two complete revolutions by hand using crankshaft pulley bolt. Feel for smooth rotation without binding or unusual resistance. Watch rocker arm operation through complete cycle - it should move smoothly without excessive clearance or binding. Check valve lash if equipped with adjustable valves (most 6.7L Cummins have hydraulic lifters with no adjustment).
    ⚠️Any binding, unusual resistance, or clicking noises indicate improper assembly. Do not start engine until cause is identified and corrected.
11. 11

    Clean and install valve cover
    Thoroughly clean valve cover and cylinder head gasket surfaces using plastic scraper. Remove all old gasket material and oil residue. Install new valve cover gasket, ensuring proper seating in cover groove. Position valve cover carefully, aligning all bolt holes. Install valve cover bolts finger-tight, then torque in proper sequence (center outward) to specification.
    Torque spec

    Cover Bolts22 Nm (16 lb-ft)
12. 12

    Refill engine oil and reconnect components
    Add the amount of engine oil that was drained during preparation (approximately 3 quarts). Reconnect any electrical connectors and fuel lines that were disconnected. Reconnect battery negative terminals. Install engine cover and air intake ducting.
13. 13

    Initial start and inspection
    Start engine and allow to idle. Listen carefully for valve train noise - new lifter may tick for 15-30 seconds until fully pumped with oil. Monitor oil pressure gauge - should reach normal pressure within 5 seconds. Check for oil leaks around valve cover. Allow engine to reach operating temperature while monitoring for unusual noises.
    ⚠️Excessive valve train noise lasting beyond 30 seconds indicates improper lifter installation or failed lifter priming. Shut down immediately and investigate.
    ⚠Low or fluctuating oil pressure may indicate oiling system problems that caused original lifter failure. Do not continue operation if oil pressure is abnormal.

Reassembly

1. Torque all fasteners to specification using proper sequence where applicable
2. Use new gasket for valve cover - do not reuse old gasket
3. Verify all electrical connectors and fuel lines are properly reconnected
4. Double-check that no tools or rags were left in engine compartment
5. If lifter noise persists beyond initial startup period, investigate immediately - do not assume it will resolve on its own

Verification

• Engine should idle smoothly with no abnormal valve train noise after initial pump-up period (30 seconds)
• Oil pressure should be normal and stable (approximately 10 psi at idle, 30+ psi at 1500 RPM)
• No oil leaks visible around valve cover gasket
• Test drive vehicle under light load - engine should respond normally with no misfires or unusual noises
• After 50-100 miles, re-check valve cover bolts for proper torque and inspect for oil leaks
• Monitor oil consumption for first 500 miles - excessive consumption may indicate additional engine problems
• If original lifter failure was due to contamination, consider oil analysis and additional filter changes during break-in period

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