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Ram Truck 1500, 2500 & 3500 (2006-2008)

Cylinder Head

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Removal & Installation



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

     

  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

  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

  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

    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



    Click image to see an enlarged view

    Fig. 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.  

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



    Click image to see an enlarged view

    Fig. 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



    Click image to see an enlarged view

    Fig. 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



Click image to see an enlarged view

Fig. 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 22 ft. lbs. (30 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.  

5.7L 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

  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.  

5.9L & 6.7L Diesel Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Raise vehicle on hoist.
  4.  
  5. Drain engine coolant.
  6.  
  7. Disconnect exhaust pipe from turbocharger elbow.
  8.  
  9. Remove turbocharger drain tube bolts at turbocharger. Cap off ports to prevent dirt or foreign material from entering.
  10.  
  11. Lower the vehicle.
  12.  
  13. Disconnect air inlet temperature/pressure sensor.
  14.  
  15. Remove air cleaner housing and snorkel from the vehicle. Cap off turbocharger air inlet to prevent intrusion of dirt or foreign material.
  16.  
  17. Disconnect cab heater core supply and return hoses from the cylinder head and heater pipe.
  18.  
  19. Disconnect turbocharger oil supply line at the turbocharger end. Cap off open ports to prevent intrusion of dirt or foreign material.
  20.  
  21. Remove exhaust manifold-to-cylinder head bolts, spacers, heat shield, retention straps, and cab heater plumbing. Remove exhaust manifold and turbocharger from the vehicle as an assembly.
  22.  
  23. Remove cooling fan/drive/shroud assembly.
  24.  
  25. Remove accessory drive belt.
  26.  
  27. Remove cooling fan support from cylinder block.
  28.  
  29. Remove upper generator bolt, loosen lower generator bolt, and rotate generator away from cylinder head.
  30.  
  31. Disconnect radiator upper hose from the thermostat housing.
  32.  
  33. Disconnect the Intake Air Temperature/Manifold Air Pressure, and Coolant Temperature sensor connectors.
  34.  
  35. Remove the engine harness to cylinder head attaching bolts and P-clips at front of head.
  36.  
  37. Remove the intake air grid heater wires from the grid heater.
  38.  
  39. Remove engine oil level indicator tube attaching bolt at fuel filter housing bracket and inlet air connection.
  40.  
  41. Remove the charge air cooler-to-air inlet housing pipe.
  42.  
  43. Remove the engine wire harness attaching bolt and wire harness push-in fastener from air inlet housing.
  44.  
  45. Remove the air inlet housing and intake grid heater from the intake manifold cover.
  46.  
  47. Remove the two grid heater harness-to-cylinder head attaching bolts at front of cylinder head.
    NOTE
    Extreme care should be used to keep dirt/debris from entering the fuel lines. Plastic caps should be used on the ends of the fuel lines.

  48.  
  49. Remove the high pressure pump to fuel rail fuel line as follows:
    1. Loosen fuel line nuts at fuel pump and at fuel rail.
    2.  
    3. Use a back-up wrench on the fitting at the fuel pump to keep it from loosening.
    4.  

  50.  
  51. Remove the fuel rail to cylinder head fuel lines as follows:
    1. Loosen No. 6 high pressure fuel line shield and position out of way.
    2.  
    3. Loosen the fuel line nuts at the fuel rail and at the cylinder head. Use a back-up wrench on HPC nut.
    4.  
    5. Remove the fuel line bracket bolts at the intake manifold cover.
    6.  

  52.  
  53. Remove the engine lift bracket from the rear of the cylinder head.
  54.  
  55. Remove the fuel rail as follows:
    1. Remove fuel rail pressure sensor connector.
    2.  
    3. Remove banjo fitting at pressure limiting valve.
    4.  
    5. Remove fuel rail bolts and fuel rail.
    6.  

  56.  
  57. Remove the low pressure lines as follows:
    1. Remove the fuel drain banjo fitting on the front side of fuel filter housing.
    2.  
    3. Remove the fuel drain banjo fitting on rear side of fuel filter housing.
    4.  
    5. Remove the fuel drain line support bracket on rear side of filter housing.
    6.  
    7. Disconnect fuel drain hose.
    8.  
    9. Remove banjo fitting at bottom of fuel filter housing.
    10.  
    11. Disconnect fuel supply hose at fuel filter.
    12.  

  58.  
  59. Disconnect fuel heater, and water in fuel sensor.
  60.  
  61. Remove the fuel filter assembly-to-cylinder head bolts and remove filter assembly from vehicle.
  62.  
  63. Remove wire harness P-clip from cylinder head (located behind filter housing).
    NOTE
    For early builds. Verify that the cylinder head cover ground spring is retained in the cylinder head cover.

  64.  
  65. Remove the cylinder head cover.
  66.  
  67. For early builds. Disconnect the rocker housing injector harness connectors.
  68.  
  69. Remove injector harness nuts from injectors.
  70.  
  71. Remove the rocker levers, cross heads and push rods. Mark each component so they can be installed in their original positions.
    NOTE
    The No. 5 cylinder exhaust and the No. 6 cylinder intake and exhaust push rods are removed by lifting them up and through the provided cowl panel access holes. Remove the rubber plugs to expose these relief holes.

  72.  
  73. Remove the fuel return line and banjo bolt at the rear of the cylinder head. Be careful not to drop the two sealing washers.
  74.  
  75. Remove the fuel injectors.
  76.  
  77. Remove rocker housing bolts and rocker housing and gasket.
  78.  
  79. Reinstall the engine lift bracket at the rear of cylinder head. Torque to 57 ft. lbs. (77 Nm).
  80.  
  81. Remove twenty six (26) cylinder head-to-block bolts.
  82.  
  83. Attach an engine lift crane to engine lift brackets and lift cylinder head off engine and out of vehicle.
  84.  
  85. Remove the head gasket and inspect for failure.
  86.  

To install:

  1. Install a new gasket with the part number side up, and locate the gasket over the dowel sleeves.
  2.  
  3. Using an engine lifting crane, lower the cylinder head onto the engine.
  4.  
  5. Lightly lubricate head bolts under bolt head and on threads, with engine oil and install. Using the sequence shown , tighten bolts in the following steps:
    1. Step 1: 52 ft. lbs. (70 Nm).
    2.  
    3. Step 2: Back off 360 degrees in sequence.
    4.  
    5. Step 3: Tighten to 77 ft. lbs. (105 Nm).
    6.  
    7. Step 4: Recheck all bolts to 77 ft. lbs. (105 Nm).
    8.  
    9. Tighten all bolts an additional 90 degrees.

      Click image to see an enlarged view

      Fig. Cylinder head torque sequence-5.9L diesel engine

    10.  

  6.  
  7. Install push rods into their original locations.
  8.  
  9. Inspect rocker housing gasket for cuts and proper installation into groove. Replace if damaged.
  10.  
  11. Install rocker housing and bolts. Tighten to 18 ft lbs. (24 Nm).
  12.  
  13. Install the fuel injectors.
  14.  
  15. Lubricate valve stem tips and install the crossheads in their original locations.
  16.  
  17. Lubricate the rocker arms and pedestals and install them in their original locations. Install the bolts and torque them to 27 ft. lbs. (36 Nm).
  18.  
  19. Verify that the valve lash settings are maintained. Refer to valve lash adjustment.
  20.  
  21. Install cylinder head cover gasket onto rocker housing.
  22.  
  23. Install injector harness nuts. Tighten to11inch lbs. (1.25 Nm).
  24.  
  25. Connect injector harness connectors at cylinder head cover gasket.
  26.  
  27. Install wire harness P-clip to cylinder head behind filter housing 18 ft. lbs. (24 Nm).
  28.  
  29. Connect the IAT/MAP sensor connector.
  30.  
  31. Install the fuel filter housing assembly and hand tighten mounting bolts, Do not torque at this time.
  32.  
  33. Connect WIF sensor, and fuel heater.
    WARNING
    Failure to follow procedure will result in fuel leaks and/or fuel system failure.

  34.  
  35. Install the fuel rail and high pressure fuel lines as follows:
    1. Hand tighten fuel rail bolts.
    2.  
    3. Hand tighten fuel drain line to pressure limiting valve. Hand tighten banjo bolt at fuel filter housing.
    4.  
    5. Hand tighten fuel rail-to-cylinder head high pressure fuel lines.
    6.  
    7. Install fuel line brace bolts-to-intake manifold finger tight for fuel lines No. 2 thru No. 5.
    8.  
    9. Install fuel line brace nut to rear lift bracket stud, finger tight, for fuel line No. 6.
    10.  
    11. Hand tighten fuel pump to fuel rail line.
    12.  
    13. Tighten fuel line nuts at cylinder head to 22 ft. lbs. (30 Nm).
    14.  
    15. Tighten fuel line nuts at fuel rail to 22 ft. lbs. (30 Nm).
    16.  
    17. Using a back up wrench, torque fuel pump to fuel rail line to 27 ft. lbs. (37 Nm). At injection pump.
    18.  
    19. Tighten fuel pump to fuel rail line to 27 ft. lbs. (37 Nm). at fuel rail.
    20.  
    21. Tighten fuel drain banjo bolt at pressure limiting valve and front of fuel filter housing to 18 ft. lbs. (24 Nm).
    22.  
    23. Tighten fuel line brace bolts to 18 ft. lbs. (24 Nm).
    24.  
    25. Tighten fuel line brace nut to 18 ft. lbs. (24 Nm).
    26.  
    27. Tighten rail bolts to 18 ft. lbs. (24 Nm).
    28.  
    29. Connect fuel pressure sensor.
    30.  
    31. Tighten fuel filter mounting bolts to 18 ft. lbs. (24 Nm).
    32.  

  36.  
  37. Reposition number 6 fuel line shield and tighten to 32 ft. lbs. (43 Nm).
  38.  
  39. Install the fuel filter to injection pump low pressure line. Inspect and replace sealing washers if necessary. Torque banjo bolts to 18 ft. lbs. (24 Nm).
  40.  
  41. Connect fuel return line at back of cylinder head hand tight.
  42.  
  43. Connect fuel return line at filter housing hand tight.
  44.  
  45. Tighten banjo connections at cylinder head and fuel filter housing to 18 ft. lbs. (24 Nm).
  46.  
  47. Install bracket to rear of filter housing. Torque to 18 ft. lbs. (24 Nm).
  48.  
  49. Using new gaskets, install the intake grid heater and air inlet housing. Tighten bolts to 18 ft. lbs. (24 Nm).
  50.  
  51. Install wire harness P-clip and push on clip to air inlet housing.
  52.  
  53. Connect engine oil level indicator tube at fuel filter housing and at air inlet housing.
  54.  
  55. Install the charge air cooler-to-air inlet housing duct assembly. Tighten all clamps to 100 inch lbs. (11 Nm).
  56.  
  57. Connect intake grid heater wires.
  58.  
  59. Secure engine harness to front of cylinder head with bolt at four locations.
  60.  
  61. Connect engine coolant temperature sensor connector.
  62.  
  63. Connect radiator upper hose to thermostat housing.
  64.  
  65. Rotate generator into position. Install upper bolt and torque upper and lower bolts.
  66.  
  67. Install wire harness push-on clip below bracket.
  68.  
  69. Install wire harness P-clip to top of bracket.
  70.  
  71. Install fan support and torque to 24 ft. lbs. (32 Nm).
  72.  
  73. Install cooling fan/drive.
  74.  
  75. Install accessory drive belt
  76.  
  77. Install exhaust manifold/turbocharger assembly, using new gaskets. Start all bolts/spacers by hand. Starting from the center bolts out, Tighten bolts to 32 ft. lbs. (43 Nm), then retighten from the center out again.
  78.  
  79. Install exhaust manifold heat shield to exhaust manifold studs. Install retaining nuts. Tighten to 18 ft. lbs. (24 Nm).
  80.  
  81. Install exhaust bolt retention straps across cylinders 5 & 6.
  82.  
  83. Using a new gasket, connect the turbocharger oil drain tube. Tighten to 18 ft. lbs. (24 Nm).
  84.  
  85. Pre-lube turbocharger with 1-2 oz. (29.9-59.14 ml) clean engine oil.
  86.  
  87. Connect the turbocharger oil supply line. Tighten to 18 ft. lbs. (24 Nm).
  88.  
  89. Install air cleaner housing and duct.
  90.  
  91. Connect air inlet temperature/pressure sensor.
  92.  
  93. Raise vehicle on hoist.
    NOTE
    Do not reuse the clamp for the exhaust pipe to turbocharger elbow connection.

  94.  
  95. Install the exhaust pipe to turbocharger elbow using a new clamp. Torque bolts to 100 in. lbs. (11 Nm).
  96.  
  97. Lower the vehicle.
  98.  
  99. Fill engine with coolant.
  100.  
  101. Start engine and check for leaks.
  102.  

 
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