Ram 1500, 2500, 3500, 2WD and 4WD, 2001-2005

Cylinder Head

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Remove or disconnect the following:
    NOTE
    Keep all valvetrain components in order for assembly.


    NOTE
    If the cylinder head is hot, gradually loosen the cylinder head bolts using the TIGHTENING sequence. If the engine is cold, then the loosening sequence for the head bolts is not important.


    NOTE
    The cylinder head bolts are different sizes. Note their locations for assembly.



    Negative battery cables
     
    Radiator hoses
     
    Heater hoses
     
    Drive belt
     
    Turbocharger
     
    Exhaust Gas Recirculation (EGR) tube
     
    Exhaust manifold
     
    Accelerator pedal position sensor
     
    Fuel lines and injector nozzles
     
    Valve cover
     



    Rocker levers and pedestal assemblies
     
    Pushrods
     
    Fuel filter and water separator assembly
     



    Cylinder head bolts
     
    Cylinder head
     

  8.  

To install:


NOTE
Check the cylinder head bolt length. If length exceeds 5.2 inches (132.1 mm), the bolt must be replaced.

  1. Install or connect the following:

    Cylinder head
     
    Pushrods
     
    Rocker levers and pedestal assemblies

    Click image to see an enlarged view

    Fig. Cylinder head torque sequence-5.9L diesel engine

    Cylinder head torque sequence-5.9L diesel engine
     

  2.  
  3. Install the cylinder head bolts and tighten them in sequence as follows:
    1. Step 1: 59 ft. lbs. (80 Nm).
    2.  
    3. Step 2: 77 ft. lbs. (104 Nm).
    4.  
    5. Step 3: Retighten to 77 ft. lbs. (80 Nm).
    6.  
    7. Step 4: Tighten an additional 90 degrees
    8.  

  4.  
  5. Install or connect the following:

    Fuel filter and water separator assembly
     
    Valve cover
     
    Fuel lines and injector nozzles
     
    Accelerator pedal position sensor
     
    Exhaust manifold
     
    EGR tube
     
    Turbocharger
     
    Drive belt
     
    Heater hoses
     
    Radiator hoses
     
    Negative battery cables
     

  6.  
  7. Fill the crankcase to the correct level.
  8.  
  9. Fill the cooling system.
  10.  
  11. Start the engine and check for leaks.
  12.  

3.7L Engine
Left Side
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Exhaust Y-pipe
     
    Intake manifold
     
    Brake booster and master cylinder
     
    Cylinder head cover
     
    Engine cooling fan and shroud
     
    Accessory drive belt
     
    Power steering pump
     

  8.  
  9. Rotate the crankshaft so that the crankshaft timing mark aligns with the Top Dead Center (TDC) mark on the front cover, and the V6 marks on the camshaft sprockets are at 12 o-clock as shown.

    Crankshaft damper
     
    Front cover

    Click image to see an enlarged view

    Fig. Camshaft sprocket timing marks-3.7L

    Camshaft sprocket timing marks-3.7L
     

  10.  
  11. Lock the secondary timing chain to the idler sprocket with Timing Chain Locking tool 8429.

    Click image to see an enlarged view

    Fig. Camshaft locking tool-3.7L

    Camshaft locking tool-3.7L
  12.  
  13. Matchmark the secondary timing chain one link on each side of the V6 mark to the camshaft sprocket.
    NOTE
    The cylinder head is retained by twelve bolts. Four of the bolts are smaller and are at the front of the head.



    Left secondary timing chain tensioner
     
    Cylinder head access plug
     
    Secondary timing chain guide
     
    Camshaft sprocket
     
    Cylinder head
     

  14.  

To install:

Click image to see an enlarged view

Fig. Examine the head bolts for signs of stretching-3.7L engine

Examine the head bolts for signs of stretching-3.7L engine

  1. Check the cylinder head bolts for signs of stretching and replace as necessary.
  2.  
  3. Lubricate the threads of the 11mm bolts with clean engine oil.
  4.  
  5. Coat the threads of the 8mm bolts with Mopar® Lock and Seal Adhesive.
  6.  
  7. Install the cylinder heads. Use new gaskets and tighten the bolts, in sequence, as follows:
    1. Step 1: Bolts 1-8 to 20 ft. lbs. (27 Nm)
    2.  
    3. Step 2: Bolts 1-10 verify torque without loosening
    4.  
    5. Step 3: Bolts 9-12 to 10 ft. lbs. (14 Nm)
    6.  
    7. Step 4: Bolts 1-8 plus 1 / 4 (90 degree) turn
    8.  
    9. Step 5: Bolts 9-12 to 19 ft. lbs. (26 Nm)

      Click image to see an enlarged view

      Fig. Cylinder head bolt torque sequence-3.7L

      Cylinder head bolt torque sequence-3.7L
    10.  

  8.  
  9. Install or connect the following:

    Camshaft sprocket. Align the secondary chain matchmarks and tighten the bolt to 90 ft. lbs. (122 Nm).
     
    Secondary timing chain guide
     
    Cylinder head access plug
     
    Secondary timing chain tensioner. Refer to the timing chain procedure in this section.
     

  10.  
  11. Remove the Timing Chain Locking tool.
  12.  
  13. Install or connect the following:

    Front cover
     
    Crankshaft damper. Torque the bolt to 130 ft. lbs. (175 Nm).
     
    Power steering pump
     
    Accessory drive belt
     
    Engine cooling fan and shroud
     
    Cover
     
    Intake manifold
     
    Exhaust Y-pipe
     
    Negative battery cable
     

  14.  
  15. Fill and bleed the cooling system.
  16.  
  17. Start the engine, check for leaks and repair if necessary.
  18.  

Right Side
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Exhaust Y-pipe
     
    Intake manifold
     
    Valve cover
     
    Engine cooling fan and shroud
     
    Accessory drive belt
     
    Oil fill housing
     
    Power steering pump
     

  8.  
  9. Rotate the crankshaft so that the crankshaft timing mark aligns with the Top Dead Center (TDC) mark on the front cover, and the V6 marks on the camshaft sprockets are at 12 o-clock as shown.

    Click image to see an enlarged view

    Fig. Crankshaft timing marks-3.7L engine

    Crankshaft timing marks-3.7L engine

    Click image to see an enlarged view

    Fig. Camshaft positioning-3.7L engine

    Camshaft positioning-3.7L engine
  10.  
  11. Remove or disconnect the following:

    Crankshaft damper
     
    Front cover
     

  12.  
  13. Lock the secondary timing chains to the idler sprocket with Timing Chain Locking tool 8429.
  14.  
  15. Matchmark the secondary timing chains to the camshaft sprockets.
  16.  
  17. Remove or disconnect the following:
    NOTE
    Each cylinder head is retained by 8 11mm bolts and four 8mm bolts.



    Secondary timing chain tensioners
     
    Cylinder head access plugs
     
    Secondary timing chain guides
     
    Camshaft sprockets
     
    Cylinder heads
     

  18.  

To install:

  1. Check the cylinder head bolts for signs of stretching and replace as necessary.
  2.  
  3. Lubricate the threads of the 11mm bolts with clean engine oil.
  4.  
  5. Coat the threads of the 8mm bolts with Mopar® Lock and Seal Adhesive.
  6.  
  7. Install the cylinder heads. Use new gaskets and tighten the bolts, in sequence, as follows:
    1. Step 1: Bolts 1-8 to 20 ft. lbs. (27 Nm)
    2.  
    3. Step 2: Bolts 1-10 verify torque without loosening
    4.  
    5. Step 3: Bolts 9-12 to 10 ft. lbs. (14 Nm)
    6.  
    7. Step 4: Bolts 1-8 plus 1 / 4 (90 degree) turn
    8.  
    9. Step 5: Bolts 9-12 to 19 ft. lbs. (26 Nm)
    10.  

  8.  
  9. Install or connect the following:

    Camshaft sprockets. Align the secondary chain matchmarks and tighten the bolts to 90 ft. lbs. (122 Nm).
     
    Secondary timing chain guides
     
    Cylinder head access plugs
     
    Secondary timing chain tensioners. Refer to the timing chain procedure in this section.
     

  10.  
  11. Remove the Timing Chain Locking tool.
  12.  
  13. Install or connect the following:

    Front cover
     
    Crankshaft damper. Torque the bolt to 130 ft. lbs. (175 Nm).
     
    Rocker arms
     
    Power steering pump
     
    Oil fill housing
     
    Accessory drive belt
     
    Engine cooling fan and shroud
     
    Valve covers
     
    Intake manifold
     
    Exhaust Y-pipe
     
    Negative battery cable
     

  14.  
  15. Fill and bleed the cooling system.
  16.  
  17. Start the engine, check for leaks and repair if necessary.
  18.  

3.9L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:
    NOTE
    Keep all valvetrain components in order for assembly.



    Negative battery cable
     
    Accessory drive belt
     
    Alternator
     
    A/C compressor, if equipped
     
    Alternator and A/C compressor bracket
     
    Air injection pump, if equipped
     
    Closed Crankcase Ventilation (CCV) system
     
    Air cleaner and hose
     
    Fuel line
     
    Accelerator linkage
     
    Cruise control cable, if equipped
     
    Transmission cable, if equipped
     
    Spark plug wires
     
    Distributor
     
    Ignition coil harness connectors
     
    Engine Coolant Temperature (ECT) sensor connector
     
    Heater hoses
     
    Bypass hose
     
    Intake manifold vacuum lines
     
    Fuel injector harness connectors
     
    Valve covers
     
    Intake manifold
     
    Exhaust front pipe
     
    Exhaust manifolds
     



    Rocker arms
     
    Pushrods
     
    Cylinder heads
     

  8.  

To install:


WARNING
Position the crankshaft so that no piston is at Top Dead Center (TDC) prior to installing the cylinder heads. Do not rotate the crankshaft during or immediately after rocker arm installation. Wait 5 minutes for the hydraulic lash adjusters to bleed down.



Click image to see an enlarged view

Fig. Cylinder head torque sequence-3.9L engine

Cylinder head torque sequence-3.9L engine
  1. Install the cylinder heads with new gaskets. Tighten the bolts in sequence as follows:
    1. Step 1: 50 ft. lbs. (68 Nm).
    2.  
    3. Step 2: 105 ft. lbs. (143 Nm).
    4.  
    5. Step 3: 105 ft. lbs. (143 Nm).
    6.  

  2.  
  3. Install or connect the following:

    Pushrods in their original locations
     
    Rocker arms in their original locations. Tighten the bolts to 21 ft. lbs. (28 Nm).
     
    Exhaust manifolds
     
    Exhaust front pipe
     
    Intake manifold
     
    Valve covers
     
    Fuel injector harness connectors
     
    Intake manifold vacuum lines
     
    Bypass hose
     
    Heater hoses
     
    ECT sensor connector
     
    Ignition coil harness connectors
     
    Distributor
     
    Spark plug wires
     
    Transmission cable, if equipped
     
    Cruise control cable, if equipped
     
    Accelerator linkage
     
    Fuel line
     
    Air cleaner and hose
     
    CCV system
     
    Air injection pump, if equipped
     
    Alternator and A/C compressor bracket
     
    Alternator
     
    A/C compressor
     
    Accessory drive belt
     
    Negative battery cable
     

  4.  
  5. Fill the cooling system.
  6.  
  7. Start the engine and check for leaks.
  8.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:
    NOTE
    Keep all valvetrain components in order for assembly.



    Negative battery cable
     
    Accessory drive belt
     
    Alternator
     
    A/C compressor, if equipped
     
    Alternator and A/C compressor bracket
     
    Air injection pump, if equipped
     
    Closed Crankcase Ventilation (CCV) system
     
    Air cleaner and hose
     
    Fuel line
     
    Accelerator linkage
     
    Cruise control cable, if equipped
     
    Transmission cable, if equipped
     
    Spark plug wires
     
    Distributor
     
    Ignition coil harness connectors
     
    Engine Coolant Temperature (ECT) sensor connector
     
    Heater hoses
     
    Bypass hose
     
    Intake manifold vacuum lines
     
    Fuel injector harness connectors
     
    Valve covers
     
    Intake manifold
     
    Exhaust front pipe
     
    Exhaust manifolds
     



    Rocker arms
     
    Pushrods
     
    Cylinder heads
     

  8.  

To install:


WARNING
Position the crankshaft so that no piston is at Top Dead Center (TDC) prior to installing the cylinder heads. Do not rotate the crankshaft during or immediately after rocker arm installation. Wait 5 minutes for the hydraulic lash adjusters to bleed down.



Click image to see an enlarged view

Fig. Cylinder head torque sequence-3.9L engine

Cylinder head torque sequence-3.9L engine
  1. Install the cylinder heads with new gaskets. Tighten the bolts in sequence as follows:
    1. Step 1: 50 ft. lbs. (68 Nm).
    2.  
    3. Step 2: 105 ft. lbs. (143 Nm).
    4.  
    5. Step 3: 105 ft. lbs. (143 Nm).
    6.  

  2.  
  3. Install or connect the following:

    Pushrods in their original locations
     
    Rocker arms in their original locations. Tighten the bolts to 21 ft. lbs. (28 Nm).
     
    Exhaust manifolds
     
    Exhaust front pipe
     
    Intake manifold
     
    Valve covers
     
    Fuel injector harness connectors
     
    Intake manifold vacuum lines
     
    Bypass hose
     
    Heater hoses
     
    ECT sensor connector
     
    Ignition coil harness connectors
     
    Distributor
     
    Spark plug wires
     
    Transmission cable, if equipped
     
    Cruise control cable, if equipped
     
    Accelerator linkage
     
    Fuel line
     
    Air cleaner and hose
     
    CCV system
     
    Air injection pump, if equipped
     
    Alternator and A/C compressor bracket
     
    Alternator
     
    A/C compressor
     
    Accessory drive belt
     
    Negative battery cable
     

  4.  
  5. Fill the cooling system.
  6.  
  7. Start the engine and check for leaks.
  8.  

4.7L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Exhaust Y-pipe
     
    Intake manifold
     
    Valve covers
     
    Engine cooling fan and shroud
     
    Accessory drive belt
     
    Oil fill housing
     
    Power steering pump
     
    Rocker arms
     

  8.  
  9. Rotate the crankshaft so that the crankshaft timing mark aligns with the Top Dead Center (TDC) mark on the front cover, and the V8 marks on the camshaft sprockets are at 12 o-clock as shown.

    Click image to see an enlarged view

    Fig. Crankshaft timing marks-4.7L engine

    Crankshaft timing marks-4.7L engine

    Click image to see an enlarged view

    Fig. Camshaft positioning-4.7L engine

    Camshaft positioning-4.7L engine
  10.  
  11. Remove or disconnect the following:

    Crankshaft damper
     
    Front cover

    Click image to see an enlarged view

    Fig. Cylinder head access plug locations-4.7L engine

    Cylinder head access plug locations-4.7L engine

    Click image to see an enlarged view

    Fig. Use the special tool to lock the timing chains on the idler gear-4.7L engine

    Use the special tool to lock the timing chains on the idler gear-4.7L engine
     

  12.  
  13. Lock the secondary timing chains to the idler sprocket with Timing Chain Locking tool 8515.
  14.  
  15. Matchmark the secondary timing chains to the camshaft sprockets.
  16.  
  17. Remove or disconnect the following:
    NOTE
    Each cylinder head is retained by ten 11mm bolts and four 8mm bolts.



    Secondary timing chain tensioners
     
    Cylinder head access plugs
     
    Secondary timing chain guides
     
    Camshaft sprockets
     
    Cylinder heads
     

  18.  

To install:

Click image to see an enlarged view

Fig. Examine the head bolts for signs of stretching-4.7L engine

Examine the head bolts for signs of stretching-4.7L engine

Click image to see an enlarged view

Fig. Cylinder head torque sequence-4.7L engine

Cylinder head torque sequence-4.7L engine

  1. Check the cylinder head bolts for signs of stretching and replace as necessary.
  2.  
  3. Lubricate the threads of the 11mm bolts with clean engine oil.
  4.  
  5. Coat the threads of the 8mm bolts with Mopar® Lock and Seal Adhesive.
  6.  
  7. Install the cylinder heads. Use new gaskets and tighten the bolts, in sequence, as follows:
    1. Step 1: Bolts 1-10 to 15 ft. lbs. (20 Nm)
    2.  
    3. Step 2: Bolts 1-10 to 35 ft. lbs. (47 Nm)
    4.  
    5. Step 3: Bolts 11-14 to 18 ft. lbs. (25 Nm)
    6.  
    7. Step 4: Bolts 1-10 plus 1 / 4 (90 degree) turn
    8.  
    9. Step 5: Bolts 11-14 to 19 ft. lbs. (26 Nm)
    10.  

  8.  
  9. Install or connect the following:

    Camshaft sprockets. Align the secondary chain matchmarks and tighten the bolts to 90 ft. lbs. (122 Nm).
     
    Secondary timing chain guides
     
    Cylinder head access plugs
     
    Secondary timing chain tensioners. Refer to the timing chain procedure in this section.
     

  10.  
  11. Remove the Timing Chain Locking tool 8515.
  12.  
  13. Install or connect the following:

    Front cover
     
    Crankshaft damper. Torque the bolt to 130 ft. lbs. (175 Nm).
     
    Rocker arms
     
    Power steering pump
     
    Oil fill housing
     
    Accessory drive belt
     
    Engine cooling fan and shroud
     
    Valve covers
     
    Intake manifold
     
    Exhaust Y-pipe
     
    Negative battery cable
     

  14.  
  15. Fill and bleed the cooling system.
  16.  
  17. Start the engine, check for leaks and repair if necessary.
  18.  

5.2L & 5.9L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:
    NOTE
    Keep valvetrain components in order for reassembly.



    Negative battery cable
     
    Accessory drive belt
     
    Alternator
     
    A/C compressor, if equipped
     
    Air injection pump, if equipped
     
    Air cleaner assembly
     
    Closed Crankcase Ventilation (CCV) system
     
    Evaporative emissions control system
     
    Fuel line
     
    Accelerator linkage
     
    Cruise control cable
     
    Transmission cable
     
    Distributor cap and wires
     
    Ignition coil wiring
     
    Engine Coolant Temperature (ECT) sensor connector
     
    Heater hoses
     
    Bypass hose
     
    Upper radiator hose
     
    Intake manifold
     
    Valve covers
     



    Rocker arms
     
    Pushrods
     
    Exhaust manifolds
     
    Spark plugs
     
    Cylinder heads
     

  6.  

To install:


WARNING
Position the crankshaft so that no piston is at Top Dead Center (TDC) prior to installing the cylinder heads. Do not rotate the crankshaft during or immediately after rocker arm installation. Wait 5 minutes for the hydraulic lash adjusters to bleed down.



Click image to see an enlarged view

Fig. Cylinder head torque sequence-5.2L and 5.9L engines

Cylinder head torque sequence-5.2L and 5.9L engines
  1. Install the cylinder heads. Use new gaskets and tighten the bolts in sequence as follows:
    1. Step 1: 50 ft. lbs. (68 Nm).
    2.  
    3. Step 2: 105 ft. lbs. (143 Nm).
    4.  
    5. Step 3: 105 ft. lbs. (143 Nm).
    6.  

  2.  
  3. Install or connect the following:

    Spark plugs
     
    Exhaust manifolds
     
    Pushrods and rocker arms in their original positions
     
    Valve covers
     
    Intake manifold
     
    Upper radiator hose
     
    Bypass hose
     
    Heater hoses
     
    ECT sensor connector
     
    Ignition coil wiring
     
    Distributor cap and wires
     
    Transmission cable
     
    Cruise control cable
     
    Accelerator linkage
     
    Fuel line
     
    Evaporative emissions control system
     
    CCV system
     
    Air cleaner assembly
     
    A/C compressor, if equipped
     
    Air injection pump, if equipped
     
    Alternator
     
    Accessory drive belt
     
    Negative battery cable
     

  4.  
  5. Fill the cooling system.
  6.  
  7. Start the engine and check for leaks.
  8.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:
    NOTE
    Keep valvetrain components in order for reassembly.



    Negative battery cable
     
    Accessory drive belt
     
    Alternator
     
    A/C compressor, if equipped
     
    Air injection pump, if equipped
     
    Air cleaner assembly
     
    Closed Crankcase Ventilation (CCV) system
     
    Evaporative emissions control system
     
    Fuel line
     
    Accelerator linkage
     
    Cruise control cable
     
    Transmission cable
     
    Distributor cap and wires
     
    Ignition coil wiring
     
    Engine Coolant Temperature (ECT) sensor connector
     
    Heater hoses
     
    Bypass hose
     
    Upper radiator hose
     
    Intake manifold
     
    Valve covers
     



    Rocker arms
     
    Pushrods
     
    Exhaust manifolds
     
    Spark plugs
     
    Cylinder heads
     

  6.  

To install:


WARNING
Position the crankshaft so that no piston is at Top Dead Center (TDC) prior to installing the cylinder heads. Do not rotate the crankshaft during or immediately after rocker arm installation. Wait 5 minutes for the hydraulic lash adjusters to bleed down.



Click image to see an enlarged view

Fig. Cylinder head torque sequence-5.2L and 5.9L engines

Cylinder head torque sequence-5.2L and 5.9L engines
  1. Install the cylinder heads. Use new gaskets and tighten the bolts in sequence as follows:
    1. Step 1: 50 ft. lbs. (68 Nm).
    2.  
    3. Step 2: 105 ft. lbs. (143 Nm).
    4.  
    5. Step 3: 105 ft. lbs. (143 Nm).
    6.  

  2.  
  3. Install or connect the following:

    Spark plugs
     
    Exhaust manifolds
     
    Pushrods and rocker arms in their original positions
     
    Valve covers
     
    Intake manifold
     
    Upper radiator hose
     
    Bypass hose
     
    Heater hoses
     
    ECT sensor connector
     
    Ignition coil wiring
     
    Distributor cap and wires
     
    Transmission cable
     
    Cruise control cable
     
    Accelerator linkage
     
    Fuel line
     
    Evaporative emissions control system
     
    CCV system
     
    Air cleaner assembly
     
    A/C compressor, if equipped
     
    Air injection pump, if equipped
     
    Alternator
     
    Accessory drive belt
     
    Negative battery cable
     

  4.  
  5. Fill the cooling system.
  6.  
  7. Start the engine and check for leaks.
  8.  

5.7L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner resonator and ducts
     
    Alternator
     
    Closed crankcase ventilation system
     
    EVAP control system
     
    Heater hoses
     
    Cylinder head covers
     
    Intake manifold
     
    Rocker arms and pushrods
     
    Cylinder heads
     

  8.  

To install:


NOTE
The head gaskets are not interchangeable. They are marked -L- and -R-.



Click image to see an enlarged view

Fig. Cylinder head torque sequence-5.7L engine

Cylinder head torque sequence-5.7L engine
  1. Install the cylinder heads. Use new gaskets and tighten the bolts, in sequence, as follows:
    1. Step 1: 12 mm bolts-25 ft. lbs. (34 Nm); 8mm bolts-15 ft. lbs. (20 Nm)
    2.  
    3. Step 2: 12mm bolts-40 ft. lbs. (54 Nm); 8mm bolts retorque-15 ft. lbs. (20 Nm)
    4.  
    5. Step 3: 12mm bolts-plus 90 degrees; 8mm bolts-25 ft. lbs. (34 Nm)
    6.  

  2.  
  3. Install or connect the following:

    Rocker arms and pushrods
     
    Intake manifold
     
    Heater hoses
     
    Alternator
     
    Cylinder head covers. Torque the studs and bolts to 70 inch lbs.
     
    Air cleaner resonator and ducts
     
    Negative battery cable
     

  4.  

8.0L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:
    NOTE
    Keep all valvetrain components in order for assembly.



    Negative battery cable
     
    Spark plug wires and heat shields
     
    Accessory drive belt
     
    Alternator
     
    A/C compressor, if equipped
     
    Alternator and A/C compressor bracket
     
    Air injection pump, if equipped
     
    Closed Crankcase Ventilation (CCV) system
     
    Evaporative Emissions (EVAP) canister vacuum lines
     
    Air cleaner and hose
     
    Fuel line
     
    Accelerator linkage
     
    Cruise control cable, if equipped
     
    Transmission cable, if equipped
     
    Ignition coil pack and bracket
     
    Temperature gauge sender connector
     
    Heater hoses
     
    Bypass hose
     
    Upper intake manifold
     
    Valve covers
     
    Exhaust Gas Recirculation (EGR) tube
     
    Lower intake manifold
     
    Exhaust front pipe
     
    Exhaust manifolds
     



    Rocker arms
     
    Pushrods
     
    Cylinder heads
     

  8.  

To install:


WARNING
Position the crankshaft so that no piston is at Top Dead Center (TDC) prior to installing the cylinder heads. Do not rotate the crankshaft during or immediately after rocker arm installation. Wait 5 minutes for the hydraulic lash adjusters to bleed down.



Click image to see an enlarged view

Fig. Cylinder head torque sequence-8.0L engine

Cylinder head torque sequence-8.0L engine
  1. Install the cylinder heads with new gaskets. Tighten the bolts in sequence as follows:
    1. Step 1: 43 ft. lbs. (58 Nm).
    2.  
    3. Step 2: 105 ft. lbs. (143 Nm).
    4.  

  2.  
  3. Install or connect the following:

    Pushrods in their original locations
     
    Rocker arms in their original locations. Tighten the bolts to 21 ft. lbs. (28 Nm).
     
    Exhaust manifolds
     
    Exhaust front pipe
     
    Lower intake manifold
     
    EGR tube
     
    Valve covers
     
    Upper intake manifold
     
    Bypass hose
     
    Heater hoses
     
    Temperature gauge sender connector
     
    Ignition coil pack and bracket
     
    Transmission cable, if equipped
     
    Cruise control cable, if equipped
     
    Accelerator linkage
     
    Fuel line
     
    Air cleaner and hose
     
    EVAP canister vacuum lines
     
    CCV system
     
    Air injection pump, if equipped
     
    Alternator and A/C compressor bracket
     
    A/C compressor, if equipped
     
    Alternator
     
    Accessory drive belt
     
    Spark plug wires and heat shields
     
    Negative battery cable
     

  4.  
  5. Fill the cooling system.
  6.  
  7. Start the engine and check for leaks.
  8.  

 
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