Cylinder Head Resurface

This procedure covers removal, inspection, and reinstallation of the cylinder head on a 2007 Ram 3500 with the 5.9L Cummins diesel engine for resurfacing to restore proper sealing and combustion chamber integrity.

Warnings

Tools required

Parts

• Cylinder head gasket × 1 — Use OEM Cummins specification
• Valve cover gasket × 1 — Use OEM specification
• Pushrod cover seals × 12 — Use OEM specification
• Injector copper washers/seals × 6 — Use OEM specification
• Injector O-rings × 6 — Use OEM specification
• Thermostat housing gasket × 1 — Use OEM specification
• Intake manifold gasket × 1 — Use OEM specification
• Exhaust manifold gasket × 1 — Use OEM specification
• Rocker lever assembly bolts × 12 — Use OEM specification
• Head bolt set (if reuse limit exceeded) × 1 — Cummins recommends inspection/replacement per service manual

Fluids

• 15W-40 diesel oil or 5W-40 synthetic — 12 qt
• HOAT coolant 50/50 — 28 qt

Preparation

1. Park vehicle on level surface and engage parking brake. Place wheel chocks behind rear wheels.
2. Disconnect negative battery cable, then positive battery cable. Secure cables away from terminals.
3. Allow engine to cool completely for at least 4 hours if recently operated.
4. Drain engine coolant completely by opening petcock at bottom of radiator and removing radiator cap slowly.
5. Drain engine oil and remove oil filter.
6. Remove engine cover/doghouse from top of engine if equipped.
7. Take detailed photos of all hose routing, electrical connections, and component positions for reassembly reference.
8. Clean work area around engine and have organized storage for all removed components with labels.

Procedure

1. 1

   Remove Air Intake System and Turbocharger Components
   Remove the air intake tube from the turbocharger inlet. Disconnect all boost tubes and intercooler piping from turbocharger outlet to intake manifold. Remove the turbocharger heat shields if present. Disconnect the turbocharger oil drain tube at the turbocharger. Label and disconnect vacuum lines and actuator linkages from turbocharger and intake system.
2. 2

   Disconnect Fuel System Components
   Allow the high-pressure common-rail system to depressurize with the engine off before disconnecting any high-pressure lines. Do NOT crack fittings to relieve pressure on a pressurized common-rail system - high-pressure diesel can cause serious injection injury. Have rags ready for residual fuel spillage. Disconnect the fuel supply and return lines at the fuel filter housing. Remove all six high-pressure fuel injector lines running from the fuel rail to each injector, and the high-pressure supply line from the CP3 pump to the rail - cap all openings immediately to prevent contamination. Label each line for cylinder position. Disconnect injector electrical connectors from each of the six fuel injectors.
   ⚠Diesel fuel will spray when loosening high-pressure lines. Wear eye protection and have absorbent materials ready.
3. 3

   Remove Valve Cover and Rocker Assembly
   Disconnect any breather tubes and wiring from the valve cover. Remove valve cover mounting bolts and carefully lift valve cover away (may need gentle prying). Remove the rocker lever assembly mounting bolts in reverse sequence from outside to inside. Carefully lift the rocker lever bridge assembly as a complete unit. Identify and mark each rocker position if disassembling. Remove all twelve pushrods and place them in a numbered rack or holder maintaining exact order (they MUST return to original positions). Inspect pushrod ends for wear.
4. 4

   Remove Intake and Exhaust Manifolds
   Disconnect all electrical sensors from intake manifold (IAT, MAP sensors, grid heater connections). Remove intake manifold mounting bolts and carefully remove intake manifold - watch for any trapped coolant. On exhaust side, spray penetrating oil on all exhaust manifold studs and allow to soak. Disconnect exhaust pipe from exhaust manifold flange. Remove exhaust manifold mounting nuts/bolts and carefully remove exhaust manifold. Inspect manifold studs for damage.
   ⚠Exhaust manifold studs are prone to breaking on this engine. Apply penetrating oil and allow adequate soak time. Heat may be necessary.
5. 5

   Disconnect Coolant System Components
   Disconnect upper radiator hose from thermostat housing. Disconnect heater hoses from cylinder head connections. Remove thermostat housing bolts and remove housing. Disconnect coolant temperature sensor wiring and remove sensor if needed for clearance. Ensure all coolant has drained from cylinder head passages.
6. 6

   Remove Fuel Injectors
   Using an injector puller slide hammer tool, carefully extract each of the six fuel injectors from the cylinder head. The injectors are secured by a hold-down clamp/retaining bolt which must be removed first; once released, the injector may still require significant extraction force. Remove and discard all injector copper sealing washers and O-rings. Cover injector bores immediately with clean rags or tape to prevent debris entry. Inspect injector bores for damage or carbon buildup.
   ⚠Never attempt to pry injectors out. Use proper injector puller tool to avoid damage to injector bores in the head.
7. 7

   Remove Cylinder Head Bolts
   Locate all cylinder head bolts (the 24-valve 5.9L Cummins uses 26 head bolts - a set of larger main bolts plus smaller perimeter bolts; verify exact count and pattern in the Cummins service manual). Loosen head bolts in the reverse of the Cummins factory tightening sequence (generally working from outside toward center), consulting the service manual for the exact pattern. Loosen each bolt 1/4 turn at a time in sequence until all are loose to prevent head warping. Remove all head bolts and keep in order. Inspect bolt threads and measure bolt length to determine if reuse is acceptable per Cummins specifications (bolts stretch and may require replacement).
   ℹ️Head bolt reuse specifications require measuring bolt length. Consult Cummins service manual for maximum allowable stretch limits.
8. 8

   Remove Cylinder Head
   Attach cylinder head lifting fixture or use engine hoist with proper rigging. The head weighs approximately 180-200 lbs. Check that all connections, bolts, and attachments have been removed. Gently pry at designated pry points (never between mating surfaces) to break head gasket seal. Carefully lift cylinder head straight up to avoid damaging dowel pins. Place cylinder head on clean padded surface with combustion chambers facing up. Remove and discard cylinder head gasket.
   ⚠️Cylinder head is extremely heavy. Use proper lifting equipment and have at least one assistant. Do not attempt to lift manually.
9. 9

   Inspect and Clean Cylinder Head Deck Surface
   Carefully clean the cylinder head mating surface using methods safe for MLS gasket surfaces (plastic scraper and approved gasket remover); avoid wire brushes or aggressive abrasives that scratch the deck and destroy the required surface finish. Remove all old gasket material. Clean all carbon deposits from combustion chambers, valve faces, and ports. Inspect head for cracks, especially between valve seats and injector bores. Use straight edge and feeler gauge to check head surface flatness across multiple directions. Measure any warpage found.
   ℹ️Maximum allowable head surface warpage is typically 0.006 inches for Cummins 5.9L. Excessive warpage requires resurfacing.
10. 10

    Prepare Cylinder Head for Machining
    If valves and valve train components need inspection, mark all components for position. Check valve stem height and spring tension if performing complete rebuild. Transport cylinder head to qualified machine shop for resurfacing. Provide machinist with Cummins specifications for maximum material removal and final surface finish requirements (typically RA 60-100 for MLS gaskets). Request pressure testing and magnaflux inspection if overheating or suspected cracks were the cause of failure.
11. 11

    Clean Engine Block Deck Surface
    With cylinder head removed, thoroughly clean engine block deck surface. Use gasket scraper carefully to avoid gouging the cast iron deck surface. Vacuum out any debris from cylinders. Cover cylinders with clean rags to prevent debris entry. Use straight edge to check block deck flatness. Clean and inspect all bolt holes using thread chaser or tap - threads must be clean and dry. Chase all head bolt threads in block with proper tap to ensure accurate torque readings.
    ⚠Prevent any debris from falling into cylinders. Even small particles can cause catastrophic engine damage.
12. 12

    Install Resurfaced Cylinder Head
    After machining is complete, inspect head surface finish. Install new cylinder head gasket on block, ensuring proper orientation (TOP marking faces up) and alignment with dowel pins. Do NOT use any sealant on head gasket. With lifting equipment, carefully lower cylinder head onto block, aligning with dowel pins. Lubricate head bolts exactly as specified in the Cummins service manual (typically clean engine oil on threads and under the bolt heads for these torque-to-yield bolts) before installation. Hand-thread all bolts before tightening any. Hand-thread all bolts before tightening any.
13. 13

    Torque Cylinder Head Bolts
    Following Cummins specified torque sequence (typically inside-out pattern), torque head bolts in multiple steps as specified in service manual. The 24-valve 5.9L Cummins uses a multi-step torque-plus-angle procedure that varies by bolt group. Obtain the exact torque values, angle steps, and sequence from the Cummins factory service manual before tightening; do not rely on generic values. Use torque angle gauge for angle tightening steps. Ensure each bolt reaches specified torque and angle. Mark bolts with paint pen after each angle step to track rotation. The 24-valve 5.9L Cummins uses torque-to-yield (angle-tightened) head bolts, which typically are not re-torqued. Follow the Cummins service manual for any required re-check or re-torque procedure.
    ⚠️CRITICAL: You MUST obtain official Cummins torque specifications and sequence from the factory service manual. Incorrect torque will result in head gasket failure or engine damage.
14. 14

    Install Fuel Injectors
    Lubricate new injector O-rings with clean diesel fuel. Install new O-rings and a new copper sealing washer on each injector. Carefully insert each injector into its original bore, then install the injector hold-down clamp and torque the hold-down bolt to Cummins specification to ensure proper seating. Injectors should sit flush or slightly below head surface. Reconnect injector electrical connectors to each injector.
15. 15

    Install Pushrods and Rocker Assembly
    Inspect cam follower bores and followers for wear. Install cam followers if removed. Lubricate each pushrod end with assembly lube or engine oil. Install each pushrod in its ORIGINAL position - order is critical. Install rocker lever assembly over pushrods, ensuring all pushrod tips seat properly in rocker sockets. Install new rocker lever assembly bolts and torque per specification (typically in inside-out sequence). Verify valve lash is within specification or adjust as required per Cummins procedure.
    ⚠Pushrods and cam followers must return to original positions. Mixing positions can cause accelerated wear or failure.

Reassembly

1. Install valve cover with new gasket, ensuring proper torque sequence on cover bolts.
2. Install intake manifold with new gasket, torquing bolts in proper sequence (typically center-out).
3. Install exhaust manifold with new gasket, using anti-seize on studs, torquing nuts in sequence.
4. Install thermostat housing with new gasket and reconnect all coolant hoses with new clamps.
5. Install all six high-pressure fuel injector lines, torquing fittings to specification (do not overtighten).
6. Reconnect fuel supply and return lines to fuel system.
7. Reinstall turbocharger components, oil drain, and all intake/boost piping.
8. Reconnect all electrical connectors, sensors, and vacuum lines per photos taken during disassembly.
9. Install new oil filter and refill engine with 12 quarts of specified diesel engine oil.
10. Refill cooling system with 28 quarts of 50/50 HOAT coolant mixture, burping system of air.
11. Reconnect battery cables (positive first, then negative).

Verification

• Before starting engine, manually rotate crankshaft two complete revolutions to verify no valve-to-piston contact.
• Prime fuel system by cranking engine without starting (may require loosening injector lines to bleed air).
• Start engine and listen for unusual noises. Engine may run rough initially due to air in fuel system.
• Check immediately for any coolant, oil, or fuel leaks around cylinder head, manifolds, and injectors.
• Allow engine to reach operating temperature while monitoring coolant level and temperature gauge.
• Check for exhaust leaks at manifold gasket.
• Verify no coolant or oil consumption after test drive.
• After 500 miles or first oil change, re-check head bolt torque if using non-TTY bolts (consult service manual).
• Monitor engine for first 1000 miles for any signs of head gasket failure (white smoke, coolant loss, overheating).

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