engine DODGE RAM SRT-10 2006 Service Repair Manual

STANDARD PROCEDURE - CAM BORE REPAIR
For standard bushings, not oversized, maximum front
cam bushing bore diameter is 59.248 mm. (2.3326
in.). DO NOT bore the intermediate cam bore to the
front cam bore oversize dimensions. Maximum front
camshaft bushing installed diameter is 54.147 mm.
(2.1318 in.). Minimum installed diameter is 54.083
mm. (2.1293 in.). Maximum intermediate camshaft
bore diameter is 54.164 mm. (2.1324 in.).
A surface finish of 2.3 micrometers (92 microinch)
must be maintained. Not more than 20% of an area of
any one bore may be 3.2 micrometers (126 micro-
inch).
Camshaft bores can be repaired individually. It is not necessary to repairundamaged cam bores in order to repair
individually damaged cam bores. The standard front bushing (1) cannot be used to repair intermediate bores.
Install all cam bushings flush or below the front and rear cam bore surface.The front camshaft bushing should be
installed flush with front face of block. The oil hole must align to allow a 3.2 mm (0.125 inch) rod to pass through
freely.
INSPECTION
Measure the combustion deck face using a straight
edge (1) and a feeler gauge (2). Cylinder block flat-
ness: End-to-end 0.076 mm ( .003 in.). Maximum vari-
ation side-to-side 0.051 mm (.002 in.).
Inspect for any localized dips or imperfections.
If the surface exceeds the limit, (Refer to 9 - ENGINE/
ENGINE BLOCK - STANDARD PROCEDURE).
BORE SPECIFICATIONS
BORE DIAMETER
Min. 102.000 mm (4.0157 in.)
Max. 102.116 mm (4.0203 in.)
OUT OF ROUNDNESS
Max. 0.038 mm (0.0015 in.)
TA P E R
Max. 0.076 mm (.003 in.)

Inspect the cylinder bores for damage or excessive wear.
Measure the cylinder bores. If the cylinder bores exceed the limit, (Referto 9 - ENGINE/ENGINE BLOCK - STAN-
DARD PROCEDURE).
Inspect the camshaft bores for scoring or excessive wear.
Measure the camshaft bores (Refer to 9 - ENGINE - SPECIFICATIONS).
If a bore exceeds the limit, (Refer to 9 - ENGINE/ENGINE BLOCK/CAMSHAFT & BEARINGS (IN BLOCK) - STAN-
DARD PROCEDURE).
Inspect the tappet bores for scoring or excessive wear.
Measure tappet bore from bottom of block. Minimum tappet bore diameter 16.000 mm (0.0630 in.). Maximum tappet
bore 16.055 mm. (0.632 in.).
If out of limits, replace the cylinder block.

CAMSHAFT & BEARINGS (IN BLOCK)
REMOVAL
CAMSHAFT BEARINGS
NOTE: Measure the diameter of each bore. If the camshaft bore for the cam bushing is worn beyond the
limit, install a new service bushing. Inspect the rest of the camshaft bores for damage or excessive wear.If
the bores without a bushing are worn beyond the limit, the engine must be removed for machining and
installation of service bushings. If badly worn, replace the cylinder block.
1. Remove the camshaft (Refer to 9 - ENGINE/ENGINE BLOCK/CAMSHAFT & BEARINGS (IN BLOCK) -
REMOVAL).
2. Remove the bushing from the No.1 bore.
3. Mark the cylinder block so you can align the oil hole in the cylinder blockwith the oil hole in the bushing.
CAMSHAFT
1. Disconnect both battery negative cables.
2. Recover A/C refrigerant (if A/C equipped) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STAN-
DARD PROCEDURE).
3. Raise vehicle on hoist.
4. Drain engine coolant into container suitable for re-use (Refer to 7 - COOLING - STANDARD PROCEDURE).
5. Lower vehicle.
6. Remove radiator upper hose.
7. Remove viscous fan/drive/shroud assembly (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - REMOVAL).
8. Disconnect the coolant recovery bottle hose from the radiator filler neck.
9. Disconnect lower radiator hose from radiator outlet.
10.Automatic Transmission models:Disconnect transmission oil cooler lines from front of radiator using Special
Tool 6931 (unless equipped with finger-release disconnect).
11. Remove radiator mounting screws and lift radiator out of engine compartment.
12. Remove upper radiator support panel.
13. If A/C equipped, disconnect A/C condenser refrigerant lines.
14. Disconnect charge air cooler piping from the cooler inlet and outlet.
15. Remove the two charge air cooler mounting bolts.
16. Remove charge air cooler (and A/C condenser if equipped) from vehicle.
17. Remove accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
18. Remove accessory drive belt tensioner.
19. Remove the fan support/hub assembly.
20. Remove crankshaft damper and speed indicator ring (Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL).
21. Remove the gear cover-to-housing bolts and gently pry the cover away from the housing, taking care not to mar
the sealing surfaces. Remove dust seal with cover.
22. Using Special Tool 7471–B Crankshaft Barring Tool, rotate the crankshaft to align the timing marks on the
crankshaft and the camshaft gears.
23. Remove the cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) -
REMOVAL).

24. Remove the rocker arms, cross heads, and push
rods. Mark each component so they can be
installed in their original positions.
NOTE: The # 5 cylinder intake and the # 6 cylinder
intake and exhaust pushrods are removed by lift-
ing them up and through the provided cowl panel
access holes. Remove the rubber plugs to expose
these relief holes.
25. Raise the tappets as follows, using the wooden
dowel rods provided withthe Miller Tool Kit 8502.
a. Insert the slotted end of the dowel rod into the
tappet.The dowel rods for the rear two cyl-
inders will have to be cut for cowl panel
clearance.Press firmly to ensure that it is
seated in the tappet.
b. Raise the dowel rod to bring the tappet to the
top of its travel, and wrap a rubber band
around the dowel rods to prevent the tappets
from dropping into the crankcase.
c. Repeat this procedure for the remaining
cylinders.
26. Verify that the camshaft timing marks are aligned
with the crankshaft mark.
27. Remove the bolts from the thrust plate.
28. Remove engine mount through bolts.
29. Install engine support fixture special tool # 8534,
and steel bracket/wing nut special tool #
8534A.
30. Raise engine enough to allow camshaft removal.
31. Remove the camshaft, gear and thrust plate.

INSPECTION
Camshaft
CAMSHAFT DIMENSIONS
CAMSHAFT DIMENSIONS
Journal diameter (No.1 and No.7)
Min. 54.028 mm. (2.127 in.)
Max. 54.048 mm. (2.128 in.)
Journal diameter (No.2 through No.6)
Min.53.962 mm. (2.1245 in.)
Max.54.013 mm. (2.1265 in.)
Diameter of peak of lobe
Intake
Min.47.175 mm (1.857 in.)
Max47.855 mm.
Exhaust
Min. 45.632 mm. (1.797 in.)
Max. 46.312 mm. (1.823 in.)
1. Inspect the valve lobes (1) and bearing journals (2)
for cracks, pitting, scoring, or generally excessive
wear. Replace any camshaft that exceeds the
allowable limits.
2. Measure the bearing journals and lobes.
CAUTION: If Camshaft lobes are worn, requiring
camshaft replacement, it is necessary to replace
the tappets also. (Refer to 9 - ENGINE/ENGINE
BLOCK/SOLID LIFTERS - REMOVAL).

Camshaft Bushing/Bores
Camshaft bores No. 2–7do notuse a bushing.
1. Inspect the camshaft bushing and bores for signs
of excessive wear.
2. Measure the camshaft bushing and bores with a
telescoping bore gauge and micrometer. If out of
specification, (Refer to 9 - ENGINE/ENGINE
BLOCK/CAMSHAFT & BEARINGS (IN BLOCK) -
REMOVAL).
3. Inspect the camshaft bushing (1) oil holes for align-
ment with cylinder block.
Camshaft Gear
Inspect the camshaft gear for cracks (gear and hub), and chipped/broken/fretted teeth. If replacement is necessary,
camshaft and gear are replaced as an assembly. (Refer to 9 - ENGINE/ENGINE BLOCK/CAMSHAFT & BEARINGS
(IN BLOCK) - REMOVAL).
Thrust Plate
CAMSHAFT THRUST PLATE THICKNESS CHART
MIN. 9.34 mm (0.368 in.)
MAX. 9.60 mm (0.378 in.)
Inspect the camshaft thrust plate for excessive wear in the camshaft contact area. Measure thrust plate thickness
using the CAMSHAFT THRUST PLATE THICKNESS CHART . Replace any thrust platethat falls outside of these
specifications:

INSTALLATION
CAMSHAFT BEARINGS
1. Apply a coating of Loctite640 Adhesive to the
backside of the new bushing. Avoid getting adhe-
sive in the oil hole.
2. Use a universal cam bushing installation tool and
install the front bushing (1) so that it is even with
the front face of the cylinder block. The oil hole
must be aligned. A 3.2 mm (0.128 inch) diameter
rod must be able to pass through the hole.
3. Measure the installed bushings at the front bore.
The minimum inside diameter is 54.083 mm
(2.1293 inch), and the maximum inside diameter is
is 54.147 mm. (2.1318 in.).
CAMSHAFT
1. Lubricate the camshaft bushing and bores with
fresh engine oil or suitable equivalent.
2. Liberally coat the camshaft lobes, journals, and
thrust washer with fresh engine oil or suitable
equivalent.
CAUTION: When installing the camshaft, DO NOT
push it in farther than it will go with the thrust
washer in place.
3. Install the camshaft and thrust plate. Align the tim-
ing marks as shown.
BACKLASH - 0.075 - 0.250 mm (0.003 - 0.010 inch)
CLEARANCE - 0.025 - 0.500 mm (0.001 - 0.020 inch)
4. Install the thrust plate bolts and tighten to 24 Nꞏm (18 ft. lbs.) torque.
5. Measure camshaft back lash and end clearance.
6. Remove the wooden dowel rods and rubber bands from the tappets.
7. Lubricate the push rods with engine oil and install in their original location.Verify that they are seated in the
tappets.
8. Lubricate the valve tips with engine oil and install the crossheads in their original locations.
9. Lubricate the crossheads and push rod sockets with engine oil and install the rocker arms and pedestals in their
original locations. Tighten bolts to 36 Nꞏm (27 ft. lbs.) torque.
10.Verify valve lash adjustment (Refer to 9 - ENGINE/CYLINDER HEAD/INTAKE/EXHAUST VALVES & SEATS
- STANDARD PROCEDURE).
11. Install the cylinder head cover. (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) -
INSTALLATION)

12. Install gear housing cover (Refer to 9 - ENGINE/VALVE TIMING/GEAR HOUSING COVER - INSTALLATION).
Install front crankshaft dust seal.
13. Install the crankshaft damper with the speed indicator ring (Refer to 9- ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - INSTALLATION).
14. Install the fan support/hub assembly Refer to (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - INSTALLA-
TION).
15. Install the power steering pump.
16. Install accessory drive belt tensioner. Torque bolt to 43 Nꞏm (32 ft. lbs.).
17. Install the accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
18. Install the charge air cooler (with a/c condenser and auxiliary transmission oil cooler, if equipped) and tighten
the mounting bolts to 2 Nꞏm (17 in. lbs.) torque.
19. Connect charge air cooler inlet and outlet pipes. Tighten clamps to 11 Nꞏm (95 in. lbs.) torque.
20. Install the radiator upper support panel.
21. Close radiator petcock and lower the radiator into the engine compartment. Tighten the mounting bolts to 11
Nꞏm (95 in. lbs.) torque.
22. Raise vehicle on hoist.
23. Connect radiator lower hose and install clamp.
24. Connect transmission auxiliary oil cooler lines (if equipped).
25. Lower vehicle.
26. Install the fandrive/shroud assembly. (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - INSTALLATION)
27. Install the coolant recovery and windshield washer fluid reservoirs to the fan shroud.
28. Connect the coolant recovery hose to the radiator filler neck.
29. Add engine coolant (Refer to 7 - COOLING - STANDARD PROCEDURE).
30. Charge A/C system with refrigerant (if A/C equipped) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING - STANDARD PROCEDURE).
31. Connect the battery negative cables.
32. Start engine and check for engine oil and coolant leaks.

CRANKSHAFT & GEAR
DESCRIPTION
The crankshaft is a forged steel, integrally balanced
unit. It is supported by seven main bearings, with posi-
tion number six designated as the thrust journal. The
crankshaft is held in place by main caps and 12 mm
capscrews. The crankshaft also has internal cross
drillings to supply the connecting rods with engine oil.
REMOVAL - GEAR
1. Remove the gear housing cover. (Refer to 9 - ENGINE/VALVE TIMING/GEAR HOUSING COVER - REMOVAL)
2. Split the gear and remove it from the crankshaft.
INSTALLATION - GEAR
1. Remove all burrs and make sure the gear surface
on the end of the crankshaft is smooth.
2. If removed, install a new alignment pin. Drive the
pin in using a ball- peen hammer, leaving it pro-
truding 1.0 mm (0.039 inch) to 1.5 mm (0.059 inch)
above the crankshaft.
WARNING: WEAR PROTECTIVE GLOVES TO PRE-
VENT INJURY.
CAUTION: DO NOT heat the gear longer than 45
minutes.
3. Heat the crankshaft gear for 45 minutes at a temperature of 149°C (300°F).Do not use torch, gear failure will
occur.
4. Apply a thin coat of lubricant to the nose of the crankshaft.
5. Position the gear with the timing mark out and install it on the crankshaft using the alignment pin. Make sure the
gear contacts the shoulder.

SEAL - CRANKSHAFT OIL - FRONT
REMOVAL
1. Disconnect both battery negative cables.
2. Raise vehicle on hoist.
3. Partially drain engine coolant into container suitable for re-use (Refer to 7 - COOLING - STANDARD PROCE-
DURE).
4. Lower vehicle.
5. Remove radiator upper hose.
6. Disconnect coolant recovery bottle hose from radiator filler neck.
7. Disconnect windshield washer pump supply hose and electrical connections and lift washer bottle off of fan
shroud.
8. Remove viscous fan/drive assembly. (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - REMOVAL).
9. Remove cooling fan shroud and fan assembly from the vehicle.
10. Remove the accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
11. Remove the cooling fan support/hub from the front of the engine.
12. Raisethevehicleonhoist.
13. Remove the crankshaft damper and speed indicator ring.
14. Remove power steering pump.
15. Remove accessory drive belt tensioner.
16. Remove the gear cover-to-housing bolts and gen-
tly pry the cover away from the housing, taking
care not to mar the gasket surfaces. Remove
crank seal dust shield with cover.
17. Support the cover on a flat work surface with
wooden blocks, and using a suitable punch (1)
and hammer, drive the old seal out of the cover
from the back side of the cover to the front side.