Fuel injector removal DODGE RAM SRT-10 2006 Service User Guide

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.

4. Install the valve spring compressor tool 8319–A
(1)as shown.
5. Compress the valve springs and install the valve
retaining locks.
6. Remove the compressor and repeat the procedure
on the remaining cylinders.
7. Install new o-ring and sealing washer on injector.
8. Lubricate o-ring and injector bore.
9. Verify sealing washer (shim) was removed with old
injector.
10. Install injector Refer to (Refer to 14 - FUEL SYS-
TEM/FUEL INJECTION/FUEL INJECTOR -
INSTALLATION).
11. Install the cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - INSTALLATION).
STANDARD PROCEDURE - VALVE LASH ADJUSTMENT AND VERIFICATION
NOTE: To obtain accurate readings, valve lash
measurements AND adjustments should only be
performed when the engine coolant temperature is
less than 60° C (140° F).
The 24–valve overhead system is a “low-maintenance”
design. Routine adjustments are no longer necessary,
however, measurement should still take place when
troubleshooting performance problems, or upon com-
pletion of a repair that includes removal and installa-
tion of the valve train components or injectors.
1. Disconnect battery negative cables.
2. Remove cylinder head cover (Refer to 9 - ENGINE/
CYLINDER HEAD/CYLINDER HEAD COVER(S) -
REMOVAL).
3. Using the crankshaft barring tool #7471–B, rotate crankshaft to align damper TDC mark to 12:00 o’clock position.
a. If both number one cylinder rocker levers are loose, continue to next step.
b. If both number one cylinder rocker levers are not loose, rotate crankshaft 360 degrees.

4. With the engine in this position, valve lash can be measured at the following rocker arms:INTAKE 1–2–4 /
EXHAUST 1–3–5. Measure the valve lash by inserting a feeler gauge between the rocker arm socket and cross-
head. Refer to VALVE LASH LIMIT CHART for the correct specifications. If the measurement fallswithinthe
limits, adjustment/resettingis notnecessary. If measurement finds the lashoutsideof the limits, adjustment/
resettingisrequired.
VALVE LASH LIMIT CHART
INTAKE EXHAUST
0.152 mm ( 0.006 in.) MIN. 0.533 mm (0.021 in.) MIN.
0.381 mm (0.015 in.) MAX. 0.863 mm (0.034 in.) MAX.
NOTE:
If measured valve lash falls within these specifications, no adjustment/reset is necessary. Engine operation within
these ranges has no adverse affect on performance, emissions, fuel economy or level of engine noise.
5. If adjustment/resetting is required, loosen the lock
nut on rocker arms and turn the adjusting screw
until the desired lash is obtained:
INTAKE0.254 mm (0.010 in.)
EXHAUST0.660 mm (0.026 in.) Tighten the lock
nut to 24 Nꞏm (18 ft. lbs.) and recheck the valve
lash.
6. Using the crankshaft barring tool, rotate thecrank-
shaftone revolution (360°) to align the damper
TDC mark to the 12 o’clock position.
7. With the engine in this position, valve lash can be
measured at the remaining rocker arms:INTAKE
3–5–6 / EXHAUST 2–4–6. Use the same method
as above for determining whether adjustment is
necessary, and adjust those that are found to be
outside of the limits.
8. Install the cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTAL-
LATION).
9. Connect the battery negative cables.
REMOVAL
1. Disconnect the battery negative cables.
2. Remove the cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
3. Disconnect the injector harness connectors at cyl-
inder head cover gasket. Remove all injector sole-
noid nuts. Remove cylinder head cover gasket.
4. Remove injector(s) for cylinder(s) to be serviced.
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
FUELINJECTOR-REMOVAL)or(Referto14-
FUEL SYSTEM/FUEL INJECTION/FUEL INJEC-
TOR - REMOVAL).
5. Remove the rocker housing.
6. Remove the rocker arms and crossheads from the
cylinder(s) to be serviced. Mark each component
so they can be installed in their original position.
7. Using the crankshaft barring tool # 7471–B (2), rotate the engine to position the damper mark in the 12 o’clock
position.At this engine position, cylinders #1 and #6 can be serviced.

8. Remove the accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
9. With the damper TDC mark in the 12 o’clock position, add a paint mark anywhere on the gear housing cover
next to the crankshaft damper. Place another mark on the vibration damper in alignment with the mark you just
made on the cover.
10. Divide the crankshaft damper into three equally sized segments as follows:
a. Using a tape measure, measure the circumference of the crankshaft damper and divide the measurement by
three (3).
b. Measure that distance in a counterclockwise direction from the first balancer mark and place another mark
on the balancer.
c. From the second damper mark, again measure in a counterclockwise direction and place a mark on the
damper at the same distance you measured when placing the second damper mark. The damper should
now be marked in three equally spaced locations and the damper TDC mark should be in the 12 o’clock
position.
d. Remove injectors, fuel lines, and high pressure connectors for every cylinder that requires repair.
11. Compress the valve springs at cylinders. # 1 and
# 6 as follows:
a. Install the valve spring compressor mounting
base as shown in.
b. Install the top plate, washer, and nut. Using a
suitable wrench tighten the nut (clockwise) to
compress the valve springs and remove the
collets.
c. Rotate the compressor nut counterclockwise to
relieve tension on springs. Remove spring
compressor.
d. Remove and replace retainers, springs, and
seals as necessary.
e.Do not rotate the engine until the springs
and retainers are reinstalled.
f. Install seals, springs and retainers. Install
spring compressor, compress valve springs and
install the collets.
g. Release the spring tension and remove the
compressor. Verify that the collets are seated
by tapping on the valve stem with a plastic
hammer.

VALVE TIMING
STANDARD PROCEDURE - TIMING VERIFICATION
1. Remove the cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) -
REMOVAL).
2. Remove fuel injector from cylindernumber 1 (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR
- REMOVAL).
3. Using Special Tool 7471B rotate the engine until the TDC mark on the damper is at 12 o’clock.
4. Using a 8 in.x 1/4 in. dowel rod inserted into cylinder number 1, rock the crankshaft back and forth to verify
piston number 1 is at TDC.
5. With cylinder number still at TDC, inspect the keyway on the crankshaft gear for proper alignment (12 o’clock
position).
6. If the keyway is not at 12 o’clock position replace the crankshaft gear assembly.
7. If the keyway is at 12 o’clock position, remove front gear cover and verify timing mark alignment between the
camshaft gear and crankshaft gear, if not aligned inspect keyway on camshaft gear.
8. Inspect keyway on camshaft gear for proper alignment with the key in the camshaft, if alignment is off replace
the camshaft/gear assembly.
9. If timing marks alignment is off and no damage is found at either the crankshaft or camshaft gear keyways,
realign timing marks as necessary.

8. Connect other end of jumper wire to positive side of battery.
9. Connect one end of a second jumper wire to remaining injector terminal.
CAUTION: Powering an injector for more than a few seconds will permanentlydamage the injector.
10. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds.
11. Place a rag or towel below fuel line quick-connect fitting at fuel rail.
12. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings.
13. Return fuel pump relay to PDC.
14. One or more Diagnostic Trouble Codes (DTC’s) may have been stored in PCMmemory due to fuel pump relay
removal. The DRB
scantoolmustbeusedtoeraseaDTC.
STANDARD PROCEDURE - DRAINING FUEL TANK - EXCEPT DIESEL
WARNING: The fuel system may be under constant fuel pressure even with the engine off. This pressure
must be released before servicing fuel tank.
Two different procedures may be used to drain fuel tank: through the fuel fill fitting on tank, or using a diagnostic
scan tool to activate the fuel pump relay. Due to a one-way check valve installed into the fuel fill opening fitting at
the tank, the tank cannot be drained conventionally at the fill cap.
The quickest draining procedure involves removing the rubber fuel fill hose at the fuel tank.
As an alternative procedure, the electric fuel pump may be activated allowingtanktobedrainedatfuelrailcon-
nection. Refer to diagnostic scan tool for fuel pump activation procedures. Before disconnecting fuel line at fuel rail,
release fuel pressure. Refer to the Fuel System Pressure Release Procedure for procedures. Attach end of special
test hose tool number 6631 or 6539 at fuel rail disconnection (tool number 6631isusedon5/16”fuellineswhile
tool number 6539 is used on 3/8” fuel lines). Position opposite end of this hose tool to an approved gasoline drain-
ing station. Activate fuel pump and drain tank until empty.
If electric fuel pump is not operating, fuel must be drained through fuel fill fitting at tank. Refer to following proce-
dures.
1. Release fuel system pressure.
2. Raise vehicle.
3. Thoroughly clean area around fuel fill fitting and rubber fuel fill hoseat tank.
4. If vehicle is equipped with 4 doors and a 6 foot (short) box, remove left-rear tire/wheel.
5. Loosen clamp and disconnect rubber fuel fill hose at tank fitting. Usingan approved gas holding tank, drain fuel
tank through this fitting.
SPECIFICATIONS
FUEL SYSTEM PRESSURE
58 psi +/- 2 psi
TORQUE - EXCEPT DIESEL
DESCRIPTION N-m Ft. Lbs. In. Lbs.
Accelerator Pedal Bracket
Mounting12 - 105
Accelerator Pedal Position
Sensor Bracket-to-Battery
Tray Bolts3-30
Crankshaft Position
Sensor - 3.7L28 21 -
Crankshaft Position
Sensor - 4.7L28 21 -

RAIL - FUEL
DESCRIPTION
The fuel injector rail is used to mount the fuel injectors to the engine.
OPERATION
High pressure from the fuel pump is routed to the fuel rail. The fuel rail then supplies the necessary fuel to each
individual fuel injector.
A quick-connect fitting with a safety latch clip is used to attach the fuel linetothefuelrail.
The fuel rail is not repairable.
CAUTION: The left and right sections of the fuel rail are connected with either a flexible connecting hose, or
joints. Do not attempt to separate the rail halves at these connecting hoseor joints. Due to the design of
the connecting hose or joint, it does not use any clamps. Never attempt to install a clamping device of any
kind to the hose or joint. When removing the fuel rail assembly for any reason, be careful not to bend or
kink the connecting hose or joint.
REMOVAL
3.7L V-6
WARNING: The fuel system is under constant pressure even with engine off. Before servicing fuel rail, fuel
system pressure must be released.
CAUTION: The left and right fuel rails are replaced as an assembly. Do not attempt to separate rail halves
at connector tubes. Due to design of tubes, it does not use any clamps. Neverattempt to install a clamping
device of any kind to tubes. When removing fuel rail assembly for any reason, be careful not to bend or
kink tubes.
1. Remove fuel tank filler tube cap.
2. Perform Fuel System Pressure Release Procedure.
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY -
STANDARD PROCEDURE)
3. Remove negative battery cable at battery.
4. Remove air duct at throttle body air box.
5. Remove air box at throttle body.
6. Remove air resonator mounting bracket at front of
throttle body (2 bolts).
7. Disconnect fuel line latch clip and fuel line at fuel
rail. A special tool will be necessary for fuel line
disconnection. (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY/QUICK CONNECT FITTING - STAN-
DARD PROCEDURE)
8. Remove necessary vacuumlines at throttle body.
9. Disconnect electrical connectors at all 6 fuel injec-
tors. To remove connector refer to. Push red col-
ored slider away from injector (1). While pushing
slider, depress tab (2) and remove connector (3)
from injector. The factory fuel injection wiring har-
ness is numerically tagged (INJ 1, INJ 2, etc.) for
injector position identification. If harness is not
tagged, note wiring location before removal.
10. Disconnect electrical connectors at all throttle body sensors.

11. Remove 6 ignition coils. (Refer to 8 - ELECTRICAL/IGNITION CONTROL/IGNITION COIL - REMOVAL)
12. Remove 4 fuel rail mounting bolts (1).
13. Gently rock and pullleftside of fuel rail until fuel
injectors just start to clear machined holes in cyl-
inder head. Gently rock and pullrightside of rail
until injectors just start to clear cylinder head
holes. Repeat this procedure (left/right) until all
injectors have cleared cylinder head holes.
14. Remove fuel rail (with injectors attached) from
engine.
15. If fuel injectors are to be removed, (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/FUEL INJEC-
TOR - REMOVAL).
4.7L V-8
WARNING: The fuel system is under constant pressure even with engine off. Before servicing fuel rail, fuel
system pressure must be released.
CAUTION: The left and right fuel rails are replaced as an assembly. Do not attempt to separate rail halves
at connector tubes. Due to design of tubes, it does not use any clamps. Neverattempt to install a clamping
device of any kind to tubes. When removing fuel rail assembly for any reason, be careful not to bend or
kink tubes.
1. Remove fuel tank filler tube cap.
2. Perform Fuel System Pressure Release Procedure.
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY -
STANDARD PROCEDURE)
3. Remove negative battery cable at battery.
4. Remove air duct at throttle body air box.
5. Remove air box at throttle body.
6. Remove air resonator mounting bracket at front of
throttle body (2 bolts).
7. Disconnect fuel line latch clip and fuel line at fuel
rail. A special tool will be necessary for fuel line
disconnection. (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY/QUICK CONNECT FITTING - STAN-
DARD PROCEDURE)
8. Remove necessary vacuumlines at throttle body.
9. Disconnect electrical connectors at all 8 fuel injec-
tors. To remove connector refer to. Push red col-
ored slider away from injector (1). While pushing
slider, depress tab (2) and remove connector (3)
from injector. The factory fuel injection wiring har-
ness is numerically tagged (INJ 1, INJ 2, etc.) for
injector position identification. If harness is not
tagged, note wiring location before removal.

10. Disconnect electrical connectors at all throttle body sensors.
11. Remove 8 ignition coils. (Refer to 8 - ELECTRICAL/IGNITION CONTROL/IGNITION COIL - REMOVAL)
12. Remove 4 fuel rail mounting bolts (1).
13. Gently rock and pullleftside of fuel rail until fuel
injectors just start to clear machined holes in cyl-
inder head. Gently rock and pullrightside of rail
until injectors just start to clear cylinder head
holes. Repeat this procedure (left/right) until all
injectors have cleared cylinder head holes.
14. Remove fuel rail (with injectors attached) from
engine.
15. If fuel injectors are to be removed, (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/FUEL INJEC-
TOR - REMOVAL).
5.7L
WARNING: The fuel system is under constant pressure even with engine off. Before servicing fuel rail, fuel
system pressure must be released. (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY- STANDARD PROCE-
DURE)
CAUTION: The left and right fuel rails are replaced as an assembly. Do not attempt to separate rail halves
at connector tube. Due to design of tube, it does not use any clamps. Never attempt to install a clamping
device of any kind to tube. When removing fuel rail assembly for any reason,be careful not to bend or kink
tube.