Ram B1500, B2500, B3500, 1999-2003

Valve Covers

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Removal & Installation



  1. Disconnect both battery negative cables.
  2.  
  3. Remove oil fill cap.
  4.  
  5. Remove the breather cover.
  6.  
  7. Disconnect the breather hose and breather drain tube from the breather housing.
  8.  
  9. Remove cylinder head cover bolts.
  10.  
  11. Remove the cylinder head cover.
    NOTE
    Verify cylinder head ground spring is still properly retained in cylinder head cover.

  12.  

To install:

  1. Inspect cylinder head cover gasket for cuts and proper installation in groove. Replace if damaged.
  2.  
  3. Position cylinder cover on top of rocker housing.
    NOTE
    Inspect rubber isolators and replace if damaged.

  4.  
  5. Install bolts. Starting with the center bolt, torque to18 ft. lbs. (24 Nm).
  6.  
  7. Install breather hose to breather.
  8.  
  9. Install breather drain hose to breather.
  10.  
  11. Install breather cover and wire harness clip. Torque to 18 ft. lbs. (24 Nm).
  12.  

  1. Disconnect the battery negative cable(s).
  2.  
  3. Remove air cleaner housing and duct work if needed for access to the valve cover(s).
  4.  
  5. Disconnect the crankcase ventilation hose from the cover, if fitted.
  6.  
  7. Remove the PCV valve from the valve cover, if equipped.
  8.  
  9. Remove any breathers, and any vacuum or emission system hoses, fitted to the cover(s).
  10.  
  11. On 4.7L engines, disconnect the injector connectors and unclip the injector harness.
  12.  
  13. Check the engine wiring relative to the valve cover(s). On some models, wiring is run along the edge of the cover(s) and secured by clips on the valve cover studs. Remove any wiring attached to the valve cover studs.
  14.  
  15. On diesels, remove the air crossover tube.
  16.  
  17. On V-10 engines, the upper intake manifold must be removed to remove the right side valve cover.
  18.  
  19. Remove the valve cover bolts and/or studs. Note locations to ease installation.
  20.  
  21. Tap the valve cover with a plastic mallet to break it loose, then carefully lift the cover off.
  22.  


WARNING
Do NOT attempt to pry the cover off. Damage to cover or gasket may result.

To install:

  1. Clean the mating surfaces.
  2.  
  3. Check covers for warpage.
  4.  
  5. Most models are equipped with reusable gaskets, normally steel-backed silicone. Replace compressed or damaged gaskets, or fill in gaps with a quality silicone sealant.
  6.  
  7. On the V-10, for the left side, the number tab is at the front of the engine with the number up. For the right side, the number tab is at the rear of the engine with the number up. Cylinder head cover fasteners have special plating. Do NOT use substitutes. Tighten to 12 ft. lbs. (16 Nm).
  8.  
  9. On the 24-valve diesel, locate the gasket with "TOP FRONT" in the proper orientation. Torque bolts to 18 ft. lbs. (24 Nm).
  10.  
  11. On 2.5L engines, tighten cover to 113 inch lbs. (13 Nm).
  12.  
  13. On 3.9L, 5.2L, and 5.7L gasoline engines, tighten fasteners to 95 inch lbs. (95 Nm).
  14.  
  15. On 4.7L engines, tighten fasteners to 105 inch lbs. (12 Nm).
  16.  
  17. Tighten cover bolts and studs evenly and in a cross pattern.
  18.  
  19. Check for leaks after several minutes of operation.
  20.  



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Fig. Remove any emission system hoses fitted to valve cover-2.5L engine shown



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Fig. Removing a PCV valve



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Fig. Removing the valve cover-V-8 engine shown



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Fig. Most valve cover gaskets are reusable



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Fig. V-10 valve cover components and fastener locations



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Fig. V-10 cover gasket installation



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Fig. Valve cover assembly-24-valve diesel

3.7L, 4.7L & 5.7L Engines
  1. Disconnect the negative battery cable.
  2.  
  3. Remove air cleaner assembly, resonator assembly and air inlet hose.
  4.  
  5. Drain cooling system to a level below the heater hoses.
  6.  
  7. Remove accessory drive belt.
  8.  
  9. Remove air conditioning compressor retaining bolts and move compressor to the left.
  10.  
  11. Remove heater hoses.
  12.  
  13. Disconnect injector and ignition coil connectors.
  14.  
  15. Disconnect and remove positive crankcase ventilation (PCV) hose.
  16.  
  17. Remove oil fill tube.
  18.  
  19. Un-clip injector and ignition coil harness and move away from cylinder head cover.
  20.  
  21. Remove right rear breather tube and filter assembly.
  22.  
  23. Remove cylinder head cover retaining bolts.
  24.  
  25. Remove cylinder head cover.
  26.  

To install:

  1. Clean cylinder head cover and both sealing surfaces. Inspect and replace gasket as necessary.
  2.  
  3. Tighten cylinder head cover bolts and double ended studs to 105 inch lbs. (12 Nm).
  4.  
  5. Install right rear breather tube and filter assembly.
  6.  
  7. Connect injector, ignition coil electrical connectors and harness retaining clips.
  8.  
  9. Install the oil fill tube.
  10.  
  11. Install PCV hose.
  12.  
  13. Install heater hoses.
  14.  
  15. Install air conditioning compressor retaining bolts.
  16.  
  17. Install accessory drive belt.
  18.  
  19. Fill the cooling system.
  20.  
  21. Install air cleaner assembly, resonator assembly and air inlet hose.
  22.  
  23. Connect battery negative cable.
  24.  

3.9L Engine
  1. Disconnect the negative cable from the battery.
  2.  
  3. Remove the engine cover.
  4.  
  5. Remove the air cleaner.
  6.  
  7. Disconnect the closed ventilation system and evaporation control system from the cylinder head cover.
  8.  
  9. Remove the cylinder head cover bolts, cover and gasket. If it-s in good condition, the gasket may be used again.
  10.  
  11. Thoroughly clean the gasket mating surfaces.
  12.  

To install:

  1. Position the cylinder head cover gasket onto the head rail.
  2.  
  3. Position the cylinder head cover onto the gasket and install the bolts. Tighten the bolts to 95 inch lbs. (11 Nm).
  4.  
  5. Install the closed crankcase ventilation system and evaporation control system.
  6.  
  7. Install the air cleaner.
  8.  
  9. Connect the negative cable to the battery.
  10.  
  11. Start engine and check for leaks.
  12.  
  13. Install engine cover.
  14.  

3.9L, 5.2L & 5.9L Engines

NOTE
A steel-backed silicone gasket is used with the cylinder head cover. This gasket can be used again.

  1. Disconnect the negative cable from the battery.
  2.  
  3. Disconnect closed ventilation system and evaporation control system from cylinder head cover.
  4.  
  5. Remove cylinder head cover bolts, cover and gasket. The gasket may be used again.
  6.  

To install:

  1. Position the cylinder head cover gasket onto the head rail.
  2.  
  3. Position the cylinder head cover onto the gasket and install the bolts. Tighten the bolts to 95 inch lbs. (11 Nm).
  4.  
  5. Install closed crankcase ventilation system and evaporation control system.
  6.  
  7. Connect the negative cable to the battery.
  8.  
  9. Start engine and check for leaks.
  10.  

5.2L & 5.9L Engines

NOTE
A reusable steel-backed silicone gasket is used with the cylinder head cover.

  1. Disconnect the negative cable from the battery.
  2.  
  3. Label and disconnect the spark plug wires form the spark plugs and set aside.
  4.  
  5. Disconnect the closed ventilation system and evaporation control system from cylinder head cover.
  6.  
  7. Remove cylinder head cover and gasket. Thoroughly clean the gasket mating surfaces.
  8.  

To install:

  1. The cylinder head cover gasket can reused. Install the gasket onto the head rail.
  2.  
  3. Position the cylinder head cover onto the gasket. Tighten the bolts to 95 inch lbs. (11 Nm).
  4.  
  5. Install the closed crankcase ventilation system and evaporation control system.
  6.  
  7. Connect the spark plug wires to the spark plugs.
  8.  
  9. Connect negative battery cable.
  10.  

8.0L Engines

NOTE
Die-cast magnesium cylinder head covers reduce noise and provide a good sealing surface. A steel backed silicon gasket is used with the cylinder head cover.

  1. Disconnect the negative cable from the battery.
  2.  
  3. Disconnect closed ventilation system and evaporation control system from cylinder head cover. Identify each system for installation.
  4.  
  5. Remove the upper intake manifold to remove the right side head cover.
  6.  
  7. Remove cylinder head cover bolts and stud bolts. Remove the covers and gaskets. The gasket may be used again.
  8.  

To install:

  1. Check the gasket for use in head cover installation. If damaged, use a new gasket.
  2.  
  3. Install the gasket onto the head rail. For the left side the number tab is at the front of engine with the number up. For the right side the number tab is at the rear of engine with the number up.
    WARNING
    The cylinder head cover fasteners have a special plating. DO NOT use alternative fasteners. Position the cylinder head cover onto the gasket. Install the stud bolts and hex head bolts in the proper positions. Tighten the stud bolts and the bolts to 144 inch lbs. (16 Nm).

  4.  
  5. If removed, install the upper intake manifold.
  6.  
  7. Install closed crankcase ventilation system and evaporation control system onto the proper head cover. DO NOT switch the systems.
  8.  
  9. Connect the negative cable to the battery.
  10.  
  11. Start engine and check for leaks.
  12.  

 
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