This procedure covers the removal and replacement of both valve cover gaskets on the 6.7L Cummins inline-6 diesel engine, including removal of air intake components and proper torque sequence.

Warnings

Tools required

Parts

• Valve cover gasket (driver side) × 1 — Use OEM Mopar specification
• Valve cover gasket (passenger side) × 1 — Use OEM Mopar specification
• Valve cover bolt grommets (set) × 1 — Use OEM specification if damaged

Preparation

1. Ensure engine is completely cool to the touch
2. Disconnect both negative battery cables from both batteries
3. Remove engine cover if equipped
4. Place drain pan under work area to catch any residual oil
5. Take photos of wiring harness routing and component locations for reassembly reference

Procedure

1. 1

   Remove air intake system components
   Loosen clamps and disconnect the air intake tube from the turbocharger inlet and air filter housing. Remove the air filter housing assembly by disconnecting any mounting brackets and vacuum lines. Set components aside in a clean area. On the passenger side, you may need to remove additional intake piping to access the valve cover.
2. 2

   Disconnect wiring harnesses and brackets
   Locate and disconnect all electrical connectors attached to or crossing over the valve covers. This includes injector harness connectors and any sensor wiring. Remove any wiring harness brackets or clips attached to the valve covers. Use your reference photos to note routing. Label connectors if needed for reassembly.
3. 3

   Remove fuel system components from valve cover area
   Carefully move fuel lines and brackets out of the way as needed. The high-pressure fuel system runs along the valve covers. You do not need to disconnect fuel lines, but may need to unbolt brackets to create clearance. Support fuel lines to prevent stress on connections.
4. 4

   Remove driver side valve cover
   Remove the valve cover bolts in a crisscross pattern starting from the outside and working inward. There are typically 16 bolts per cover. Carefully lift the valve cover off the cylinder head. If stuck, gently tap with a rubber mallet or use a plastic pry tool at the designated pry points. Do not pry between sealing surfaces. Note the position of any locating dowels.
5. 5

   Remove passenger side valve cover
   Repeat the valve cover bolt removal process for the passenger side. Remove bolts in a crisscross pattern from outside to inside. Lift the cover carefully. The passenger side may have additional clearance challenges due to firewall proximity. Work carefully to avoid damaging fuel lines or wiring.
6. 6

   Clean gasket mating surfaces
   Using a gasket scraper and wire brush, carefully remove all old gasket material from both valve cover mating surfaces and cylinder head surfaces. Be extremely careful not to gouge or scratch the aluminum head sealing surface. Clean surfaces thoroughly with brake cleaner and wipe with clean, lint-free rags. Inspect for any damage, warping, or cracks. The mating surfaces must be completely clean and dry.
7. 7

   Inspect valve covers and prepare new gaskets
   Inspect both valve covers for warping by placing on a flat surface. Check bolt holes and grommets for damage. Replace any damaged bolt grommets. Verify new gaskets match the old gaskets exactly. Position new gaskets on the valve covers (they typically seat in a groove in the cover itself). Ensure gaskets are properly seated all the way around before installation.
8. 8

   Install driver side valve cover
   Carefully position the driver side valve cover with new gasket onto the cylinder head. Align any locating dowels. Install all valve cover bolts hand-tight first. Once all bolts are started, torque in the proper sequence: start from the center and work outward in a crisscross pattern. Torque all bolts evenly in at least two passes, final pass to specification.
   Torque spec

   Cover Bolts22 Nm (16 lb-ft)
9. 9

   Install passenger side valve cover
   Position the passenger side valve cover with new gasket onto the cylinder head. Align locating dowels and install all bolts hand-tight. Torque in the proper sequence starting from the center and working outward in a crisscross pattern. Make at least two torque passes, bringing all bolts to final specification evenly.
   Torque spec

   Cover Bolts22 Nm (16 lb-ft)
10. 10

    Reinstall fuel system brackets and lines
    Reattach any fuel line brackets that were removed, ensuring proper routing and no contact with sharp edges or hot components. Torque mounting bolts to specification if applicable. Verify fuel lines are properly supported and secured.
11. 11

    Reconnect wiring harnesses
    Reinstall all wiring harness brackets and reconnect all electrical connectors following your reference photos. Ensure all connectors click fully into place and are properly secured. Route harnesses away from moving components and heat sources. Reinstall any protective covers or looms.
12. 12

    Reinstall air intake system
    Reinstall the air filter housing assembly and connect all mounting brackets. Reconnect the air intake tube to the turbocharger inlet and air filter housing. Tighten all clamps securely. Ensure no vacuum lines or connectors were missed.
13. 13

    Final inspection and battery reconnection
    Perform a final visual inspection of all work areas. Verify all tools are removed from engine bay. Confirm all connectors are attached and all bolts are torqued. Reinstall engine cover if equipped. Reconnect both negative battery cables to both batteries.

Reassembly

1. Valve cover bolts must be torqued in sequence from center outward in a crisscross pattern
2. Make at least two torque passes to ensure even gasket compression
3. Do not reuse old valve cover gaskets - always install new gaskets
4. Ensure all wiring harness routing matches original configuration to prevent chafing or interference

Verification

• Start the engine and allow it to idle for several minutes while observing both valve covers for any signs of oil leakage
• Check around all bolt locations and gasket edges for seepage
• Verify no unusual noises or check engine lights are present
• After initial run, allow engine to cool and re-check valve cover bolt torque after first heat cycle
• Monitor for leaks over the next few days of operation, checking after engine is fully warmed and again when cold

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