Cylinder Head R&R

Complete removal and reinstallation of the cylinder head on a 2007 Ram 3500 with 5.9L Cummins diesel engine, including valve train disassembly and head gasket replacement.

Warnings

Tools required

Parts

• Cylinder head gasket × 1 — Use OEM Cummins specification
• Head bolt set (if reusing, inspect for stretch) × 1 — Use OEM Cummins specification
• Valve cover gasket × 1 — Use OEM specification
• Exhaust manifold gasket × 1 — Use OEM specification
• Intake manifold gasket set × 1 — Use OEM specification
• Injector O-ring and seal kit (all 6 cylinders) × 1 — Use OEM Cummins specification
• Thermostat housing gasket × 1 — Use OEM specification
• Rocker lever shaft seals × 1 — Use OEM specification
• Coolant crossover tube O-rings × 1 — Use OEM specification
• Engine oil × 1 — 15W-40 diesel or 5W-40 synthetic
• Coolant × 1 — HOAT 50/50 premix

Fluids

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

Preparation

1. Disconnect both batteries (negative terminals first) and remove battery hold-down on driver side battery for access
2. Drain engine coolant completely from radiator petcock and block drain plugs
3. Drain engine oil and remove oil filter
4. Remove engine cover and air intake system from turbocharger to air filter housing
5. Relieve fuel system pressure by loosening fuel filter drain valve
6. Support engine with hoist or fixture from above - cylinder head removal will unbalance engine mounts
7. Raise and support vehicle on jack stands if removing exhaust manifold from underneath
8. Clean entire valve cover and cylinder head area thoroughly to prevent debris entry

Procedure

1. 1

   Remove valve cover and upper engine components
   Disconnect engine wiring harnesses from injectors and sensors. Remove charge air cooler outlet tube from intake manifold. Disconnect coolant hoses from thermostat housing and coolant crossover. Remove fuel supply and return lines from cylinder head (cap all openings immediately). Remove the valve cover bolts (verify count against factory service manual) and carefully lift valve cover off, tapping gently with rubber mallet if stuck.
2. 2

   Remove rocker lever assembly
   Mark rocker lever positions for reassembly. Loosen rocker shaft bolts evenly in multiple passes working from ends toward center to prevent shaft warping. Remove rocker shaft pedestals with rocker levers as an assembly. Store rocker levers in order if reusing. Remove pushrods and store in order - they must be reinstalled in original positions. Inspect pushrod ends for wear or damage.
3. 3

   Remove intake and exhaust manifolds
   Disconnect turbocharger oil drain tube and coolant lines. Remove exhaust manifold-to-turbocharger mounting nuts (may require penetrating oil and heat). Remove intake manifold bolts and lift manifold off (it may be stuck with carbon deposits). Remove exhaust manifold bolts working from center outward. Inspect manifold studs in cylinder head - replace any damaged studs before reinstalling head.
4. 4

   Remove fuel injectors
   Remove injector hold-down bolts (internal Torx). If injectors are seized, attach slide hammer/injector puller to injector body and tap firmly while applying upward pressure. Do not pry on injector bodies. Once removed, immediately cap injector nozzles and cylinder head openings. Remove and discard all injector copper sealing washers and O-rings. Clean injector bores thoroughly with brass brush.
5. 5

   Disconnect remaining cylinder head components
   Remove coolant temperature sensor and other sensors from cylinder head. Disconnect heater hose connections. Remove fuel crossover line and banjo bolts. Remove any remaining wiring brackets, ground straps, or accessory brackets attached to cylinder head. Verify all connections to cylinder head are disconnected before proceeding.
6. 6

   Remove cylinder head bolts
   Loosen cylinder head bolts in reverse of tightening sequence (work from outside toward center in multiple passes). The 5.9L Cummins cylinder head is retained by a set of torque-to-yield head bolts (verify exact count and arrangement against the factory service manual before removal). Remove bolts completely and store in order. Inspect bolt threads for damage and measure bolt length to check for stretch - replace any bolt exceeding the maximum length specified in the factory service manual. Clean bolt threads in block with thread chaser and compressed air.
7. 7

   Remove cylinder head
   Carefully break cylinder head loose from block using pry points at front and rear corners (do not pry between head and block surfaces). Once loose, lift head straight up using engine hoist with lifting bracket or strap under intake ports. Head weighs approximately 250 lbs - use proper lifting equipment. Place head on clean padded surface with combustion chambers facing up. Remove and discard head gasket.
8. 8

   Inspect and clean mating surfaces
   Inspect cylinder head deck surface for warpage using precision straight edge and feeler gauges (check lengthwise, crosswise, and diagonally). Maximum warpage is 0.004 inches - exceeding this requires machining. Clean head and block mating surfaces completely using plastic scraper and solvent - no gasket material or carbon can remain. Do not use abrasive pads that could scratch surfaces. Blow out all coolant and oil passages with compressed air. Cover cylinders with clean shop towels to prevent debris entry.
9. 9

   Install new head gasket and position cylinder head
   Verify block surface is completely clean and dry. Install new head gasket on block with 'TOP' marking facing up - gasket is not symmetrical and must be oriented correctly. Align gasket dowel pins with holes in block. Carefully lower cylinder head onto block using hoist, aligning with dowel pins. Guide head into position without sliding it across gasket surface.
10. 10

    Install and torque cylinder head bolts
    Lightly oil head bolt threads and underside of bolt heads with clean engine oil. Install all head bolts finger-tight. Following the factory torque sequence, torque bolts in the multi-step method (initial torque passes followed by angle passes) exactly as specified in the factory service manual - do not rely on generic values for these critical torque-to-yield fasteners. Install and torque perimeter bolts to specification. Replace head bolts per factory service manual guidance; do not reuse any bolt that exceeds the stretch limit.
11. 11

    Install fuel injectors with new seals
    Install new copper sealing washers in injector bores (must be below flush with head surface). Install new O-rings on injector bodies lubricated with clean diesel fuel. Carefully insert injectors into bores ensuring they seat fully on copper washers. Install injector hold-down clamps and torque hold-down bolts to the specification listed in the factory service manual. Verify injectors do not bind and sit flush with head surface.
12. 12

    Install pushrods and rocker assembly
    Install pushrods in their original positions, seating ball ends in lifter sockets. Apply assembly lube to rocker arm contact points and rocker shaft. Position rocker shaft assembly on pedestals, aligning with pushrods. Install rocker shaft pedestal bolts and torque evenly in multiple passes from center outward to the specification listed in the factory service manual. Verify pushrods rotate freely and are properly seated.
13. 13

    Install manifolds and remaining components
    Install new exhaust manifold gasket and position exhaust manifold. Torque manifold bolts from center outward per specification. Install new intake manifold gaskets and position intake manifold. Torque intake bolts evenly per specification. Reconnect turbocharger to exhaust manifold with new gasket. Install fuel supply and return lines with new sealing washers. Reconnect all coolant hoses, sensors, and wiring harnesses.
14. 14

    Install valve cover and complete assembly
    Clean valve cover mating surface thoroughly. Install new valve cover gasket (ensure gasket sealing beads are properly positioned in gasket grooves). Position valve cover and install bolts finger-tight. Torque valve cover bolts in cross pattern to the specification listed in the factory service manual (do not overtighten - overtightening will damage the cover or gasket). Reconnect charge air tube, engine cover, and air intake system. Install new oil filter and refill with specified diesel engine oil (12 quarts). Refill cooling system with HOAT coolant 50/50 mix (verify total system capacity against factory specification). Reconnect batteries (positive first, then negative).

Reassembly

1. All torque specifications must be obtained from factory service manual as they are critical to proper engine operation and not available in this database
2. Head bolts must be torqued in proper sequence and with angle torque method - improper torquing will cause head gasket failure
3. Pushrods and rocker levers should be reinstalled in original positions to maintain wear patterns
4. All fuel system connections must be torqued to specification to prevent high-pressure fuel leaks
5. Cooling system must be properly bled of air after refilling to prevent overheating

Verification

• Prime fuel system using lift pump until fuel filter is full and lines are purged of air
• Verify no coolant, oil, or fuel leaks around cylinder head before starting engine
• Start engine and allow to idle - check immediately for leaks at head gasket, valve cover, manifolds, and injectors
• Monitor coolant temperature and verify thermostat opens properly - burp cooling system as needed
• Check for exhaust leaks at manifold gasket and turbocharger connection
• Listen for unusual valve train noise that could indicate incorrect pushrod installation or inadequate lubrication
• After engine reaches operating temperature and is shut off, recheck all fluid levels when cool
• Road test vehicle under load and verify normal power delivery and no overheating
• Recheck valve cover bolt torque after first heat cycle as gasket may compress slightly

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