DODGE RAM SRT-10 2006 Service Repair Manual

AIR CLEANER ELEMENT
REMOVAL
Testing Air Cleaner Element using Filter Minder™
Do not attempt to unnecessarily remove top of air
cleaner housing for air cleaner element inspection
on diesel engines.
The air cleaner (filter) housing (5) is equipped with an
air Filter Minder™ gauge (3). This air flow restriction
gauge will determine when air cleaner element is
restricted and should be replaced.
The Filter Minder™ (5) consists of a diaphragm and
calibrated spring sealed inside of a plastic housing. A
yellow colored disc (2) attached to diaphragm moves
along a graduated scale on side of Filter Minder. After
the engine has been shut off, a ratcheting device
located within Filter Minder will hold yellow disc at
highest restriction that air cleaner element has experi-
enced. A drop in air pressure due to an air cleaner
element restriction moves diaphragm and yellow disc
will indicate size of air drop.
CAUTION: Certain engine degreasers or cleaners
may discolor or damage plastic housing of Filter
Minder. Cover and tape Filter Minder if any engine
degreasers or cleaners are to be used.
To test, turn engine off. If yellow disc (2) has reached
red colored zone (3) on graduated scale, air cleaner
element should be replaced. Refer to Removal /
Installation.
Resetting Filter Minder:After air cleaner (filter) ele-
ment has been replaced, press rubber button on top of Filter Minder. This will allow yellow colored disc to reset.
After button has been pressed, yellow disc should spring back to UP position.
If Filter Minder gauge has reached red colored zone, and after an examination of air cleaner (filter) element, ele-
ment appears to be clean, high reading may be due to a temporary condition such as snow build-up at air intake.
Temporary high restrictions may also occur if air cleaner (filter) element has gotten wet such as during a heavy rain
or snow. If this occurs, allow element to dry out during normal engine operation. Reset rubber button on top of Filter
Minder and retest after element has dried.

Filter Removal
1. The housing cover is equipped with spring clips
and is hinged with plastic tabs. Unlatch clips from
top of air cleaner housing and tilt housing cover up
for cover removal.
2. Remove air cleaner element from air cleaner hous-
ing (5).
INSTALLATION
1. Before installing new air cleaner element (filter), clean inside of aircleaner housing.
2. Position air cleaner cover to tabs on front of air cleaner housing. Latchspring clips to seal cover to housing.

CYLINDER HEAD
DESCRIPTION
The cylinder head is constructed of cast iron and is a one piece cross flow design with four valves per cylinder. The
arrangement of two intake and two exhaust valves per cylinder allows for a centrally located injector. The cylinder
head also includes an integral intake manifold, an integral thermostat housing, and a longitudal fuel return rifle,
which exits at the rear of the head. The 24 valve design also includes integrally cast valve guides and hardened
intake and exhaust valve seat inserts.
REMOVAL
1. Disconnect battery negative cables.
2. Raise vehicle on hoist.
3. Drain engine coolant.
4. Disconnect exhaust pipe from turbocharger elbow.
5. Remove turbocharger drain tube bolts at turbocharger. Cap off ports to prevent dirt or foreign material from enter-
ing.
6. Lower vehicle.
7. Disconnect air inlet temperature/pressure sensor.
8. Remove air cleaner housing and snorkel from the vehicle. Cap off turbocharger air inlet to prevent intrusion of
dirt or foreign material.
9. Disconnect cab heater core supply and return hoses from the cylinder head and heater pipe.
10. Disconnect turbocharger oil supply line at the turbocharger end. Cap off open ports to prevent intrusion of dirt
or foreign material.
11. Remove exhaust manifold-to-cylinder head bolts, spacers, heat shield, retention straps, and cab heater plumb-
ing. Remove exhaust manifold and turbocharger from the vehicle as an assembly.
12. Remove cooling fan/drive/shroud assembly. (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - REMOVAL)
13. Remove accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
14. Remove cooling fan support from cylinder block.
15. Remove upper generator bolt, loosen lower generator bolt, and rotate generator away from cylinder head.
16. Disconnect radiator upper hose from the thermostat housing.
17. Disconnect the Intake Air Temperature/Manifold Air Pressure, and Coolant Temperature sensor connectors.
18. Remove the engine harness to cylinder head attaching bolts and P-clipsat front of head.
19. Remove the intake air grid heater wires from the grid heater.
20. Remove engine oil level indicator tube attaching bolt at fuel filter housing bracket and inlet air connection..
21. Remove the charge air cooler-to-air inlet housing pipe.
22. Remove the engine wire harness attaching bolt and wire harness push-infastener from air inlet housing.
23. Remove the air inlet housing and intake grid heater from the intake manifold cover.
24. 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.
25.Remove the high pressure pump to fuel rail fuel line as follows:
a. Loosen fuel line nuts at fuel pump and at fuel rail.
b. Use a back-up wrench on the fitting at the fuel pump to keep it from loosening.
26. Remove the fuel rail to cylinder head fuel lines as follows:
a. Loosen No. 6 high pressure fuel line shield and position out of way.
b. Loosen the fuel line nuts at the fuel rail and at the cylinder head. Use a back-up wrench on HPC nut.
c. Remove the fuel line bracket bolts at the intake manifold cover.

27. Remove the engine lift bracket from the rear of the cylinder head.
28. Remove the fuel rail as follows:
a. Remove fuel rail pressure sensor connector.
b. Remove banjo fitting at pressure limiting valve.
c. Remove fuel rail bolts and fuel rail.
29. Remove the low pressure lines as follows:
a. Remove the fuel drain banjo fitting on the front side of fuel filter housing.
b. Remove the fuel drain banjo fitting on rear side of fuel filter housing.
c. Remove the fuel drain line support bracket on rear side of filter housing.
d. Disconnect fuel drain hose.
e. Remove banjo fitting at bottom of fuel filter housing.
f. Disconnect fuel supply hose at fuel filter.
30. Disconnect fuel heater, and water in fuel sensor.
31. Remove the fuel filter assembly-to-cylinder head bolts and remove filter assembly from vehicle.
32. 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.
33. Remove the cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) -
REMOVAL).
34.For early builds.Disconnect rocker housing injector harness connectors.
35. Remove injector harness nuts from injectors.

36. Remove the rocker levers (1), cross heads and
push rods. Mark each component so they can be
installed in their original positions.
NOTE: The #5 cylinder exhaust and the #6 cylinder
intake and exhaust push rods are removed by lift-
ing them up and through the provided cowl panel
access holes. Remove the rubber plugs to expose
these relief holes.
37. Remove the fuel return line and banjo bolt at the rear of the cylinder head. Be careful not to drop the two (2)
sealing washers.
38. Remove the fuel injectors (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR - REMOVAL).
39. Remove rocker housing bolts and rocker housing and gasket.
40. Reinstall the engine lift bracket at the rear of cylinder head. Torque to77Nꞏm(57ft.lbs.).
41. Remove twenty six (26) cylinder head-to-block bolts.
42. Attach an engine lift crane to engine lift brackets and lift cylinder head off engine and out of vehicle.
43. Remove the head gasket and inspect for failure.
CLEANING
CLEANING
CAUTION: Do not wire brush head surface while fuel injectors are still installed. Fuel injector damage can
result.
Remove fuel injectors before cleaning (if not already removed during cylinder head removal).
Clean the carbon from the injector nozzle seat with a nylon or brass brush.
Scrape the gasket residuefrom all gasket surfaces.
Wash the cylinder head in hot soapy water solution (88°C or 140°F).
After rinsing, use compressed air to dry the cylinder head.
Polish the gasket surface with 400 grit paper. Use an orbital sander or sanding block to maintain a flat surface.
CLEANING—CROSSHEADS
Clean all crossheads in a suitable solvent. If necessary, use a wire brush or wheel to remove stubborn deposits.
Rinse in hot water and blow dry with compressed air.
CLEANING—PUSHRODS
Clean the pushrods in a suitable solvent. Rinse in hot water and blow dry with compressed air. If necessary, use a
wire brush or wheel to remove stubborn deposits.

INSPECTION
INSPECTION
Inspect the cylinder head for cracks in the combustion
surface. Pressure test any cylinder head that is visibly
cracked. A cylinder head that is cracked between the
injector bore and valve seat can be pressure tested
and reused if OK; however, if the crack extendsinto
the valve seat insert bore, the cylinder headmustbe
replaced.
Visually inspect the cylinder block and head combus-
tion surfaces for localized dips or imperfections. Check
the cylinder head and block combustion surfaces for
overall out-of-flatness. If either the visual or manual
inspection exceeds the limits, then the head or block
must be surfaced.
Check the top surface for damage caused by the cylinder head gasket leakingbetween cylinders.
Inspect the block and head surface for nicks, erosion, etc.
Check the head distortion. Maximum overall variation end to end is 0.305 mm(0.012 inch), and maximum overall
variationsidetoside0.076mm(.003in.).
DO NOT proceed with the in-chassis overhaul if the cylinder head or block surface is damaged or not flat (within
specifications).
Check block surface for distortion. Maximum variation end-to-end is 0.076 mm ( .003 in.), side-to-side 0.051 mm
(.002).
Visually inspect the cylinder head bolts for damaged
threads, corroded/pitted surfaces, or a reduced diam-
eter due to bolt stretching.
If the bolts are not damaged, their “free length” should
be measured using the cap screw stretch gauge pro-
vided with the replacement head gasket. Place the
head of the bolt against the base of the slot and align
the bolt with the straight edge of gauge. If the end of
the bolt touches the foot of the gauge, the boltmust
be discarded.The maximum bolt free length is
132.1 mm (5.200 in.).
INSPECTION - CROSSHEADS
Inspect the crossheads for cracks and/or excessive
wear on rocker lever and valve tip mating surfaces.
Replace any crossheads that exhibit abnormal wear or
cracks.

INSPECTION—PUSHRODS
Inspect the pushrod ball and socket for signs of scor-
ing. Check for cracks where the ball and the socket
are pressed into the tube.
Roll the pushrod on a flat work surface with the socket
end hanging off the edge. Replace any pushrod that
appears to be bent.
INSTALLATION
WARNING: THE OUTSIDE EDGE OF THE HEAD
GASKET IS VERY SHARP. WHEN HANDLING THE
NEW HEAD GASKET, USE CARE NOT TO INJURE
YOURSELF.
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:
a. Torqueboltsto70Nꞏm(52ft.lbs.).
b. Back off 360 degrees in sequence.
c. Torque bolts to 105 Nꞏm (77 ft. lbs.).
d. Re-check all bolts to 105 Nꞏm (77 ft. lbs.).
e. Tighten all bolts an additional
1⁄4turn (90°).

4. Install push rods into their original locations.Ve r i f y
that they are seated in the tappets.
5. Inspect rocker housing gasket for cuts and proper installation into groove. Replace if damaged.
6. Install rocker housing and bolts. Tighten to 24 Nꞏm (18 lb. ft.).
7. Install fuel injector (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR - INSTALLATION).
8. Lubricate valve stem tips and install the cross-
heads in their original locations.
9. Lubricate the rocker arms (1) and pedestals (2)
and install them in their original locations. Install
the bolts and torque them to 36 Nꞏm (27 ft. lbs.).
10. Verify that the valve lash settings are maintained
(Refer to 9 - ENGINE/CYLINDER HEAD/INTAKE/
EXHAUST VALVES & SEATS - STANDARD
PROCEDURE).
11. Install cylinder head cover gasket onto rocker housing.
12. Install injector harness nuts. Tighten to 1.25 Nꞏm (11 in. lbs.).
13. Connect injector harness connectors at cylinder head cover gasket.
14. Install wire harness P-clip to cylinder head behind filter housing 24 Nꞏm (18 ft. lbs.).
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.
CAUTION: Failure to follow procedure will result in fuel leaks and/or fuelsystem failure.
18.Install the fuel rail and high pressure fuel lines as follows:
a. Hand tighten fuel rail bolts.
b. Hand tighten fuel drain line to pressure limiting valve. Hand tighten banjo bolt at fuel filter housing.
c. Hand tighten fuel rail-to-cylinder head high pressure fuel lines.

d. Install fuel line brace bolts-to-intake manifold finger tight for fuellines#2thru#5.
e. Install fuel line brace nut to rear lift bracket stud, finger tight, for fuel line #6.
f. Hand tighten fuel pump to fuel rail line.
g. Torque fuel line nuts at cylinder head to 30 Nꞏm ( 22 ft. lbs.).
h. Torque fuel line nuts at fuel rail to 30 Nꞏm (22 ft. lbs.)
i. Usingabackupwrench,torquefuelpumptofuelraillineto37Nꞏm(27ft.lbs.). At injection pump.
j. Torque fuel pump to fuel rail line to 37 Nꞏm (27 ft. lbs.) at fuel rail.
k. Torque fuel drain banjo bolt at pressure limiting valve and front of fuelfilter housing to 24 Nꞏm (18 ft. lbs.).
l. Torque fuel line brace bolts to 24 Nꞏm (18 ft. lbs.).
m. Torque fuel line brace nut to 24 Nꞏm (18 ft. lbs.).
n. Torque rail bolts to 24 Nꞏm (18 ft. lbs.).
o. Connect fuel pressure sensor.
p. Torque fuel filter mounting bolts to 24 Nꞏm (18 ft. lbs.).
19. Reposition number 6 fuel line shield and torque to 43 Nꞏm (32 ft. lbs.).
20. Install the fuel filter to injection pump low pressure line. Inspect and replace sealing washers if necessary.
Torque banjo bolts to 24 Nꞏm (18 ft. lbs.).
21. Connect fuel return line at back of cylinder head hand tight.
22. Connect fuel return line at filter housing hand tight.
23. Torque banjo connections at cylinder head and fuel filter housing to 24Nꞏm (18 ft. lbs.)
24. Install bracket to rear of filter housing. Torque to 24 Nꞏm (18 ft. lbs.).
25. Using new gaskets, install the intake grid heater and air inlet housing. Torque bolts to 24 Nꞏm (18 ft. lbs.).
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. Torque all clamps to 11 Nꞏm (100 in. lbs.).
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 32 Nꞏm (24 ft. lbs.).
37. Install cooling fan/drive refer to (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - INSTALLATION).
38. Install accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
39. Install exhaust manifold/turbocharger assembly, using new gaskets.Start all bolts/spacers by hand. Starting
from the center bolts out, Torque bolts to 43 Nꞏm (32 ft. lbs.), then retorque from the center out again.
40. Install exhaust manifold heat shield to exhaust manifold studs. Install retaining nuts.Torque to 24 Nꞏm (18 ft.
lbs.).
41. Install exhaust bolt retention straps across cylinders 5 & 6.
42. Using a new gasket, connect the turbocharger oil drain tube. Torque to 24Nꞏm(18ft.lbs.).
43. Perform the turbocharger pre-lube procedure. (Refer to 11 - EXHAUST SYSTEM/TURBOCHARGER SYSTEM/
TURBOCHARGER - INSTALLATION)
44. Connect the turbocharger oil supply line. Torque to 24 Nꞏm (18 ft. lbs.).
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 11 Nꞏm (100 in. lbs.).
49. Lower vehicle.
50. Fill engine coolant (Refer to 7 - COOLING - STANDARD PROCEDURE).
51. Start engine and check for leaks.