Head Gasket - Single

This procedure replaces the cylinder head gasket on a 2007 Ram 3500 with the 5.9L Cummins diesel engine, including removal and installation of the cylinder head and associated components.

Warnings

Tools required

Parts

• Cylinder head gasket × 1 — Use OEM specification
• Cylinder head bolts (TTY) × 1 — Use OEM specification - torque-to-yield type
• Exhaust manifold gasket × 1 — Use OEM specification
• Intake manifold gasket × 1 — Use OEM specification
• Valve cover gasket × 1 — Use OEM specification
• Injector o-rings and seals kit × 1 — Use OEM specification
• Thermostat housing gasket × 1 — Use OEM specification
• Anti-seize compound × 1 — High-temperature rated

Fluids

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

Preparation

1. Ensure engine is completely cool to the touch
2. Disconnect both battery cables, negative first
3. Drain engine coolant completely from radiator and block drain plugs
4. Drain engine oil and remove oil filter
5. Remove engine cover and air intake system
6. Relieve fuel system pressure by loosening fuel filter drain valve
7. Position engine hoist or support fixture to assist with cylinder head removal
8. Take detailed photos of wiring harness routing and component positions
9. Have a clean, organized workspace prepared for removed components

Procedure

1. 1

   Remove valve cover and rocker assembly
   Remove valve cover bolts and carefully lift off valve cover. Remove rocker arm assembly bolts in reverse of tightening sequence (outside to inside). Lift off rocker lever assembly and pushrod guide plate as a unit. Remove all 12 pushrods and keep them in order for reinstallation in their original positions. Inspect pushrod ends for wear.
2. 2

   Disconnect fuel system components
   Disconnect high-pressure fuel lines from all six injectors. Cap all open fuel ports immediately to prevent contamination. Disconnect fuel return line. Remove fuel filter housing and bracket assembly from cylinder head. Disconnect fuel injector electrical connectors and carefully move wiring harness aside.
   ⚠️Even with pressure relieved, residual fuel pressure may be present. Keep face and body away from connections during loosening.
3. 3

   Remove intake and exhaust manifolds
   Remove intake manifold grid heater and disconnect intake manifold bolts. Remove intake manifold and set aside with gasket. Remove exhaust manifold heat shield. Remove exhaust manifold nuts working from center outward. Carefully remove exhaust manifold and gasket. Inspect manifold mounting studs for damage.
   Torque spec

   Intake Manifold Bolts25 Nm (18 lb-ft)

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

   Disconnect remaining cylinder head components
   Disconnect upper radiator hose from thermostat housing. Remove thermostat housing bolts and housing. Disconnect engine oil supply and return lines from turbocharger (if removing head on turbo side). Remove engine lift bracket from rear of cylinder head. Disconnect any remaining coolant lines, sensors, or brackets attached to cylinder head.
   ⚠Label all sensor connectors with tape and marker to ensure correct reconnection.
5. 5

   Remove cylinder head bolts
   Using a breaker bar, loosen all 26 cylinder head bolts in the reverse of the tightening sequence (work from outside toward center in three stages). Remove all bolts completely and set aside for disposal. These are torque-to-yield bolts and must NOT be reused. Inspect bolt holes in block for debris or damage.
   ⚠Loosen head bolts gradually in sequence to prevent warping. Do not attempt to remove any bolt completely until all are loosened.
6. 6

   Remove cylinder head
   With assistance or engine hoist, carefully break cylinder head free from block using pry points (never pry between sealing surfaces). Lift cylinder head straight up and off the block. Place on padded work surface with combustion chambers facing up. Do not lay head on its gasket surface.
   ⚠️Cylinder head weighs approximately 150 lbs. Use proper lifting technique and assistance to prevent injury.
7. 7

   Clean and inspect mating surfaces
   Using plastic gasket scraper, carefully remove all old gasket material from both cylinder head and block deck surfaces. Clean surfaces thoroughly with solvent and allow to dry. Use shop vacuum to remove any debris from cylinder bores. Inspect block deck surface with straight edge and feeler gauge for warpage (maximum allowable is 0.004 inches over entire length). Inspect cylinder head deck surface similarly. If warpage exceeds specification, head must be machined. Avoid gouging the cast iron sealing surfaces; use appropriate gasket removal tools. Do not allow debris to fall into cylinder bores or oil passages.
   ⚠Never use metal scrapers on aluminum surfaces. Do not allow debris to fall into cylinder bores or oil passages.
8. 8

   Inspect and prepare cylinder head
   With head removed, inspect valves, valve seats, and combustion chambers for carbon buildup, cracks, or damage. Check valve stem seals for deterioration. If significant wear or damage is present, cylinder head should be professionally serviced before reinstallation. Clean the head bolt threaded holes in the engine block with a proper thread chaser to ensure accurate torque readings. Blow out holes with compressed air. Blow out holes with compressed air.
   ℹ️This is the ideal time to perform valve service if needed. Consider measuring valve spring pressure and stem height if engine has high mileage.
9. 9

   Install new head gasket and position cylinder head
   Verify block surface is completely clean and dry. Position new cylinder head gasket on block, ensuring all alignment dowels engage properly and all coolant and oil passages align. Do NOT use any sealant on head gasket. Head gasket orientation is critical. Verify the gasket orientation markings per the Cummins service manual and that the front of the gasket aligns with the front of the engine. Carefully lower cylinder head onto block, engaging alignment dowels. Ensure head is fully seated before installing bolts.
   ⚠Head gasket orientation is critical. Verify TOP marking faces up and front of gasket aligns with front of engine.
10. 10

    Install and torque cylinder head bolts
    Install all 26 NEW cylinder head bolts finger-tight. Using torque wrench, tighten all bolts to the manufacturer-specified Step 1 torque per the Cummins ISB service manual, following the correct sequence from center outward. Next, tighten all bolts to the specified Step 2 torque in the same sequence. Using angle gauge, rotate each bolt the manufacturer-specified additional angle in sequence. Verify all torque and angle values against the current Cummins ISB service manual before proceeding.l of 180 degrees additional rotation.
    ⚠Tightening sequence is critical. Begin at center bolts and work outward in spiral pattern. Ensure angle gauge is properly zeroed before each angle measurement.
    Torque spec

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

    Cylinder Head Bolts - Step 280 Nm (59 lb-ft)

    Cylinder Head Bolts - Step 30 Nm (0 lb-ft) + 90°

    Cylinder Head Bolts - Step 40 Nm (0 lb-ft) + 90°
11. 11

    Reinstall pushrods and rocker assembly
    Install each pushrod in its original location, ensuring lower end properly seats in lifter cup. Install pushrod guide plate. Position rocker lever assembly over pushrods, ensuring each rocker properly engages its pushrod. Install rocker assembly bolts and tighten from center outward to specification per service manual. Verify all rockers move freely and pushrods are properly seated.
    ⚠Pushrods must be installed in original positions. Mix-up can cause valve train damage.
12. 12

    Install intake and exhaust manifolds
    Position new exhaust manifold gasket and install exhaust manifold. Install manifold bolts with hardened washers and torque to the Cummins-specified value (approximately 43 Nm / 32 lb-ft) in the specified sequence, verifying against the service manual. Install new intake manifold gasket and position intake manifold. Install intake manifold bolts and torque to the Cummins-specified value in proper sequence, verifying against the service manual. Install exhaust manifold heat shield and grid heater.
    Torque spec

    Exhaust Manifold Nuts25 Nm (18 lb-ft)

    Intake Manifold Bolts25 Nm (18 lb-ft)
13. 13

    Reconnect fuel system and remaining components
    Install new injector o-rings and seals using light coating of clean diesel fuel as lubricant. Reconnect high-pressure fuel lines to all injectors and torque per specification. Reconnect fuel return line. Reinstall fuel filter housing assembly. Install new thermostat housing gasket and thermostat housing, connecting upper radiator hose. Reconnect all coolant lines, sensors, and wiring harnesses using photos taken during disassembly. Install turbo oil lines if previously removed.
    ⚠Ensure all injector o-rings seat properly. Improper sealing will cause fuel leaks and hard starting.
14. 14

    Install valve cover and complete assembly
    Install new valve cover gasket on valve cover. Position valve cover on cylinder head and install bolts. Torque valve cover bolts to specification in criss-cross pattern. Reconnect any remaining electrical connectors, breather hoses, and brackets. Install air intake system and engine cover. Reconnect battery cables, positive first.

Reassembly

1. Double-check all electrical connectors are properly seated and secured
2. Verify all fuel line connections are tight and properly torqued
3. Ensure no tools or parts are left in engine compartment
4. Verify all coolant drain plugs are reinstalled and tight

Verification

• Refill cooling system with 28 quarts of HOAT 50/50 coolant, burping system to remove air pockets
• Install new oil filter and refill engine with 12 quarts of 15W-40 diesel oil
• Turn ignition to ON position without starting to prime fuel system, cycle 3-4 times
• Start engine and immediately check for fuel, oil, or coolant leaks around all connections
• Allow engine to reach operating temperature while monitoring for leaks and unusual noises
• Check for proper oil pressure on gauge within 5 seconds of startup
• Verify no coolant mixing with oil (check for milky appearance in oil or oil film in coolant)
• After engine reaches operating temperature, shut off and allow to cool, then recheck all fluid levels
• Perform a test drive and recheck for leaks after engine has cooled
• Monitor engine for first 500 miles for any signs of gasket failure, oil consumption, or coolant loss

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