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Replace Cylinder head on Dodge 5.9L & 6.7L Diesel Engines?

Dodge Truck RAM diesel engine cylinder head replacing.

The procedure with details and diagram.


  1. Raise vehicle on hoist.
  2. Drain engine coolant.
  3. Disconnect exhaust pipe from turbocharger elbow.
  4. Remove turbocharger drain tube bolts at turbocharger. Cap off ports to prevent dirt or foreign material from entering.
  5. Lower the vehicle.
  6. Disconnect air inlet temperature/pressure sensor.
  7. Remove air cleaner housing and snorkel from the vehicle. Cap off turbocharger air inlet to prevent intrusion of dirt or foreign material.
  8. Disconnect cab heater core supply and return hoses from the cylinder head and heater pipe.
  9. Disconnect turbocharger oil supply line at the turbocharger end. Cap off open ports to prevent intrusion of dirt or foreign material.
  10. 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.
  11. Remove cooling fan/drive/shroud assembly.
  12. Remove accessory drive belt.
  13. Remove cooling fan support from cylinder block.
  14. Remove upper generator bolt, loosen lower generator bolt, and rotate generator away from cylinder head.
  15. Disconnect radiator upper hose from the thermostat housing.
  16. Disconnect the Intake Air Temperature/Manifold Air Pressure, and Coolant Temperature sensor connectors.
  17. Remove the engine harness to cylinder head attaching bolts and P-clips at front of head.
  18. Remove the intake air grid heater wires from the grid heater.
  19. Remove engine oil level indicator tube attaching bolt at fuel filter housing bracket and inlet air connection.
  20. Remove the charge air cooler-to-air inlet housing pipe.
  21. Remove the engine wire harness attaching bolt and wire harness push-in fastener from air inlet housing.
  22. Remove the air inlet housing and intake grid heater from the intake manifold cover.
  23. 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.
  24. 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. Use a back-up wrench on the fitting at the fuel pump to keep it from loosening.
  25. 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. Loosen the fuel line nuts at the fuel rail and at the cylinder head. Use a back-up wrench on HPC nut.
    3. Remove the fuel line bracket bolts at the intake manifold cover.
  26. Remove the engine lift bracket from the rear of the cylinder head.
  27. Remove the fuel rail as follows:
    1. Remove fuel rail pressure sensor connector.
    2. Remove banjo fitting at pressure limiting valve.
    3. Remove fuel rail bolts and fuel rail.
  28. Remove the low pressure lines as follows:
    1. Remove the fuel drain banjo fitting on the front side of fuel filter housing.
    2. Remove the fuel drain banjo fitting on rear side of fuel filter housing.
    3. Remove the fuel drain line support bracket on rear side of filter housing.
    4. Disconnect fuel drain hose.
    5. Remove banjo fitting at bottom of fuel filter housing.
    6. Disconnect fuel supply hose at fuel filter.
  29. Disconnect fuel heater, and water in fuel sensor.
  30. Remove the fuel filter assembly-to-cylinder head bolts and remove filter assembly from vehicle.
  31. 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.
  32. Remove the cylinder head cover.
  33. For early builds. Disconnect the rocker housing injector harness connectors.
  34. Remove injector harness nuts from injectors.
  35. 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.
  36. Remove the fuel return line and banjo bolt at the rear of the cylinder head. Be careful not to drop the two sealing washers.
  37. Remove the fuel injectors.
  38. Remove rocker housing bolts and rocker housing and gasket.
  39. Reinstall the engine lift bracket at the rear of cylinder head. Torque to 57 ft. lbs. (77 Nm).
  40. Remove twenty six (26) cylinder head-to-block bolts.
  41. Attach an engine lift crane to engine lift brackets and lift cylinder head off engine and out of vehicle.
  42. Remove the head gasket and inspect for failure.
To install:
  1. Install a new gasket with the part number side up, and locate the gasket over the dowel sleeves.
  2. Using an engine lifting crane, lower the cylinder head onto the engine.
  3. 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. Step 2: Back off 360 degrees in sequence.
    3. Step 3: Tighten to 77 ft. lbs. (105 Nm).
    4. Step 4: Recheck all bolts to 77 ft. lbs. (105 Nm).
    5. Tighten all bolts an additional 90 degrees. 

      image
      Fig. Cylinder head torque sequence-5.9L diesel engine
  4. Install push rods into their original locations.
  5. Inspect rocker housing gasket for cuts and proper installation into groove. Replace if damaged.
  6. Install rocker housing and bolts. Tighten to 18 ft lbs. (24 Nm).
  7. Install the fuel injectors.
  8. Lubricate valve stem tips and install the crossheads in their original locations.
  9. 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).
  10. Verify that the valve lash settings are maintained. Refer to valve lash adjustment.
  11. Install cylinder head cover gasket onto rocker housing.
  12. Install injector harness nuts. Tighten to11inch lbs. (1.25 Nm).
  13. Connect injector harness connectors at cylinder head cover gasket.
  14. Install wire harness P-clip to cylinder head behind filter housing 18 ft. lbs. (24 Nm).
  15. Connect the IAT/MAP sensor connector.
  16. Install the fuel filter housing assembly and hand tighten mounting bolts, Do not torque at this time.
  17. Connect WIF sensor, and fuel heater.
    WARNING
    Failure to follow procedure will result in fuel leaks and/or fuel system failure.
  18. Install the fuel rail and high pressure fuel lines as follows:
    1. Hand tighten fuel rail bolts.
    2. Hand tighten fuel drain line to pressure limiting valve. Hand tighten banjo bolt at fuel filter housing.
    3. Hand tighten fuel rail-to-cylinder head high pressure fuel lines.
    4. Install fuel line brace bolts-to-intake manifold finger tight for fuel lines No. 2 thru No. 5.
    5. Install fuel line brace nut to rear lift bracket stud, finger tight, for fuel line No. 6.
    6. Hand tighten fuel pump to fuel rail line.
    7. Tighten fuel line nuts at cylinder head to 22 ft. lbs. (30 Nm).
    8. Tighten fuel line nuts at fuel rail to 22 ft. lbs. (30 Nm).
    9. Using a back up wrench, torque fuel pump to fuel rail line to 27 ft. lbs. (37 Nm). At injection pump.
    10. Tighten fuel pump to fuel rail line to 27 ft. lbs. (37 Nm). at fuel rail.
    11. Tighten fuel drain banjo bolt at pressure limiting valve and front of fuel filter housing to 18 ft. lbs. (24 Nm).
    12. Tighten fuel line brace bolts to 18 ft. lbs. (24 Nm).
    13. Tighten fuel line brace nut to 18 ft. lbs. (24 Nm).
    14. Tighten rail bolts to 18 ft. lbs. (24 Nm).
    15. Connect fuel pressure sensor.
    16. Tighten fuel filter mounting bolts to 18 ft. lbs. (24 Nm).
  19. Reposition number 6 fuel line shield and tighten to 32 ft. lbs. (43 Nm).
  20. 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).
  21. Connect fuel return line at back of cylinder head hand tight.
  22. Connect fuel return line at filter housing hand tight.
  23. Tighten banjo connections at cylinder head and fuel filter housing to 18 ft. lbs. (24 Nm).
  24. Install bracket to rear of filter housing. Torque to 18 ft. lbs. (24 Nm).
  25. Using new gaskets, install the intake grid heater and air inlet housing. Tighten bolts to 18 ft. lbs. (24 Nm).
  26. Install wire harness P-clip and push on clip to air inlet housing.
  27. Connect engine oil level indicator tube at fuel filter housing and at air inlet housing.
  28. Install the charge air cooler-to-air inlet housing duct assembly. Tighten all clamps to 100 inch lbs. (11 Nm).
  29. Connect intake grid heater wires.
  30. Secure engine harness to front of cylinder head with bolt at four locations.
  31. Connect engine coolant temperature sensor connector.
  32. Connect radiator upper hose to thermostat housing.
  33. Rotate generator into position. Install upper bolt and torque upper and lower bolts.
  34. Install wire harness push-on clip below bracket.
  35. Install wire harness P-clip to top of bracket.
  36. Install fan support and torque to 24 ft. lbs. (32 Nm).
  37. Install cooling fan/drive.
  38. Install accessory drive belt
  39. 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.
  40. Install exhaust manifold heat shield to exhaust manifold studs. Install retaining nuts. Tighten to 18 ft. lbs. (24 Nm).
  41. Install exhaust bolt retention straps across cylinders 5 & 6.
  42. Using a new gasket, connect the turbocharger oil drain tube. Tighten to 18 ft. lbs. (24 Nm).
  43. Pre-lube turbocharger with 1-2 oz. (29.9-59.14 ml) clean engine oil.
  44. Connect the turbocharger oil supply line. Tighten to 18 ft. lbs. (24 Nm).
  45. Install air cleaner housing and duct.
  46. Connect air inlet temperature/pressure sensor.
  47. Raise vehicle on hoist.
    NOTE
    Do not reuse the clamp for the exhaust pipe to turbocharger elbow connection.
  48. Install the exhaust pipe to turbocharger elbow using a new clamp. Torque bolts to 100 in. lbs. (11 Nm).
  49. Lower the vehicle.
  50. Fill engine with coolant.
  51. Start engine and check for leaks.

These details will help.
Thanks.           

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html


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