How to replace Cylinder head on Dodge Ram Truck?

The Procedure for 5.2L & 5.9L Engine.
The Procedure mentioned Covers Dodge Ram 1500, 2500, 3500, 2WD & 4WD. Its For 2001 – 2005 Year Models.

1. Drain the cooling system.
2. Drain the engine oil.
3. 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

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 
   
   
   

   Fig. Cylinder head torque sequence-5.9L diesel engine
2. Install the cylinder head bolts and tighten them in sequence as follows:
   1. Step 1: 59 ft. lbs. (80 Nm).
   2. Step 2: 77 ft. lbs. (104 Nm).
   3. Step 3: Retighten to 77 ft. lbs. (80 Nm).
   4. Step 4: Tighten an additional 90 degrees
3. 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
4. Fill the crankcase to the correct level.
5. Fill the cooling system.
6. Start the engine and check for leaks.

==================================

5.2L & 5.9L Engines

1. Before servicing the vehicle, refer to the Precautions Section.
2. Drain the cooling system.
3. 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

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.

 

Fig. 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. Step 2: 105 ft. lbs. (143 Nm).
   3. Step 3: 105 ft. lbs. (143 Nm).
2. 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
3. Fill the cooling system.
4. Start the engine and check for leaks.

These details will help.

Thanks.           

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