Valve Cover Gasket - Single

This procedure covers removal and replacement of the valve cover gasket on the 5.9L Cummins diesel engine, including removal of components obstructing access and proper torque sequence for reassembly.

Warnings

Tools required

Parts

• Valve cover gasket × 1 — Use OEM Cummins gasket or equivalent
• Valve cover bolt grommets (if deteriorated) × 1 — Use OEM specification

Fluids

• 15W-40 diesel oil or 5W-40 synthetic — 1 qt

Preparation

1. Ensure engine is completely cool to the touch
2. Disconnect negative battery cable
3. Remove engine cover if equipped
4. Clean excess dirt and debris from valve cover and surrounding areas to prevent contamination

Procedure

1. 1

   Remove air intake components
   Loosen clamp at air filter housing and turbocharger inlet. Remove intake tube assembly to gain access to valve cover area. Set aside in clean area.
2. 2

   Disconnect electrical connections and fuel lines
   Disconnect injector wiring harness connectors. Unclip harness from valve cover routing clips. Move wiring harness aside and secure away from work area. Verify whether fuel supply/return lines route through or attach to the valve cover on this engine, and disconnect them as required before removal.
3. 3

   Remove breather and vent tubes
   Disconnect crankcase breather tube from valve cover. Remove any PCV or vent hoses attached to valve cover. Note routing for reinstallation.
4. 4

   Position oil drain pan
   Place large oil drain pan beneath valve cover area. Some residual oil may be present in and around the valve cover and will spill when the cover is removed. Position the pan to catch this oil.
   ⚠Failure to use adequate drain pan capacity will result in significant oil spillage onto engine and frame components.
5. 5

   Remove valve cover bolts
   Remove the valve cover bolts in a crisscross pattern starting from the outer bolts working inward. Verify the exact valve cover bolt count against service documentation before removal; the 5.9L Cummins uses fewer fasteners than many engines. Remove all bolts, keeping them organized. Keep bolts organized and inspect rubber grommets for deterioration.
6. 6

   Remove valve cover
   Carefully lift valve cover straight up to avoid damaging injector tubes. Oil will drain from cover into pan. Tilt cover to drain remaining oil completely. Inspect internal baffles and drain-back passages for debris.
7. 7

   Remove old gasket and clean surfaces
   Remove old valve cover gasket from both cover and cylinder head mating surfaces. Use plastic scraper or gasket remover to avoid gouging the sealing surfaces. Clean all surfaces thoroughly with brake cleaner and lint-free towels. Ensure no debris falls into engine.
8. 8

   Inspect mating surfaces
   Inspect the composite valve cover and cast-iron cylinder head sealing surfaces for warpage, cracks, or damage. Check valve cover for cracks, especially around bolt holes. Verify all injector tube seals are in good condition.
9. 9

   Install new gasket
   Position new valve cover gasket onto cylinder head. Ensure gasket is properly seated in all areas and aligns with bolt holes. Do not use sealant unless specified by gasket manufacturer - most modern gaskets are dry-install type.
10. 10

    Install valve cover
    Carefully lower valve cover onto gasket, ensuring proper alignment with all injector tubes and bolt holes. Avoid shifting cover once seated to prevent gasket displacement.
11. 11

    Install and torque valve cover bolts
    Install all valve cover bolts with grommets finger-tight. Tighten bolts in sequence from center outward in a crisscross pattern to ensure even gasket compression. Torque all bolts to specification in multiple passes, tightening evenly; verify the final valve cover bolt torque against Cummins/Mopar service documentation before finalizing.
    Torque spec

    Valve Cover Bolts10 Nm (7 lb-ft)
12. 12

    Reconnect breather and vent systems
    Reinstall crankcase breather tube to valve cover ensuring proper seal. Reconnect all vent hoses and PCV components as originally routed.
13. 13

    Reconnect electrical and fuel connections
    Route injector wiring harness along valve cover and secure in original routing clips. Reconnect all injector electrical connectors ensuring they click into place. Reconnect any fuel return lines removed earlier.
14. 14

    Reinstall air intake components
    Reinstall air intake tube assembly between air filter housing and turbocharger inlet. Tighten clamps securely. Ensure no vacuum leaks at connections.
15. 15

    Refill engine oil and check level
    Add approximately 1 quart of appropriate diesel engine oil to compensate for oil lost during valve cover removal. Start engine and allow to idle for 2-3 minutes, then shut off and recheck oil level. Adjust to proper level on dipstick.

Reassembly

1. Torque valve cover bolts in multiple passes from center outward to ensure even gasket compression and prevent leaks
2. Verify all electrical connectors are fully seated and wiring harness is properly routed and secured
3. Double-check all hose and tube connections are secure before starting engine

Verification

• Reconnect battery and start engine, allowing it to idle for 5 minutes while monitoring for oil leaks around valve cover perimeter
• Check for proper engine oil level after run time and top off if necessary
• Verify no oil seepage from valve cover gasket area after engine reaches operating temperature
• Confirm no vacuum leaks from intake system and all breather/vent systems are functioning properly

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