DODGE RAM SRT-10 2006 Service Repair Manual

MANIFOLD - INTAKE
REMOVAL
1. Disconnect the battery negative cables.
2. Remove the charge air cooler outlet tube (6) from
the air inlet housing (8).
3. Remove the engine oil dipstick tube mounting bolt.
4. Remove dipstick support at fuel filter housing. Posi-
tion dipstick tube to the side.
5. Disconnect the air grid heater power cables at the
cable mounting studs.
6. Remove the engine wiring harness connections at
the air inlet housing elbow.
7. Remove the four (4) air inlet housing mounting
bolts and remove the housing from top of the
heater elements.
8. Remove the intake air grid heater (1)from the
manifold.
9. Remove the high pressure fuel lines and fuel rail (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL LINES
- REMOVAL).
10. Disconnect manifold air temperature/pressure sensor connector.
11. Remove the remaining intake manifold cover-to-cylinder head bolts.
12. Remove the intake manifold cover and gasket. Keep the gasket material and any other material out of the air
intake.
13. Clean the intake manifold cover and cylinder head sealing surface.

CLEANING
Clean manifold in solvent and blow dry with compressed air.
Clean cylinder block gasket surfaces using a suitable solvent.
The plenum pan rail must be clean and dry (free of all foreign material).
INSPECTION
Inspect manifold for cracks.
Inspect mating surfaces of manifold for flatness with a straightedge.
INSTALLATION
1. Using a new gasket, install the intake manifold cover.
2. Install the cover-to-cylinder head bolts that do not hold down the fuel rail.Tightentheboltsto24Nꞏm(18ft.lbs.)
torque.
3. Install the high pressure rail and fuel lines (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL LINES -
INSTALLATION).
4. Using two (2) new gaskets, install the intake air grid heater and air inlet housing.
5. Connect the manifold air temperature/pressure sensor connector.
6. Install and tighten the air intake heater power supply nut to 14 Nꞏm (120 in. lbs.) torque.
7. Install oil dipstick tube support at fuel filter housing.
8. Install the engine oil dipstick tube and mounting bolt.
9. Position the charge air cooler outlet tube onto the air inlet housing. Tightentheclampsto11Nꞏm(100in.lbs.)
torque.
10. Attach the engine wire harness to the air inlet housing.
11. Prime the fuel system. Refer to the fuel priming procedure in Group 14, Fuel System.
12. Connect the battery negative cables.

MANIFOLD - EXHAUST
REMOVAL
1. Disconnect the battery negative cables.
2. Raise vehicle on hoist.
3. Disconnect the exhaust pipe from the turbocharger
elbow.
4. Disconnect oil drain tube from turbocharger.
5. Lower vehicle.
6. Disconnect the electronic wastegate command
valve from harness.
7. Disconnect the turbocharger air inlet hose.
8. Remove air cleaner assembly.
9. Disconnect the turbocharger oil supply line.
10. Disconnect the charge air cooler inlet pipe from
the turbocharger.
11. Remove the turbocharger and gasket from the
exhaust manifold.
12. Remove the cab heater return pipe nut from the
exhaust manifold stud. Position the tube out of the
way.
13. Remove heat shield.
14. Remove exhaust manifold bolt lockplates (1).
15. Remove the exhaust manifold-to-cylinder head
bolts(2,6) and spacers (3).
16. Remove the exhaust manifold and gaskets.
CLEANING
Clean the cylinder head and exhaust manifold sealing surfaces with a suitable scraper. Use a Scotch-Brite™ pad or
equivalent.
INSPECTION
Inspect the exhaust manifold for cracks. Measure the exhaust manifold forflatness. Place a ruler over all of the
exhaust ports and insert a feeler gauge between the port flange and the ruler. Maximum deviation from flat is 0.20
mm (.008 inch).
INSTALLATION
1. Using new exhaust manifold gaskets, install the exhaust manifold. Install the bolts and spacers and tighten the
bolts in the sequence shown in to 43 Nꞏm (32 ft. lbs.) torque.
2. Retorque the four center bolts.
3. Install heat shield and torque nuts to 24 Nm (18 ft. lbs.).
4. Install cab heater tube.
5. Install exhaust manifold bolt retention straps.
6. Install the cab heater return tube brace to the manifold bolt stud. Tighten the nut to 24 Nꞏm (18 ft. lbs.) torque.
7. Install the turbocharger and a new gasket. Tighten the turbocharger mountingnutsto43Nꞏm(32ft.lbs.)torque.
8. Raise vehicle on hoist.
9. Install the oil drain tube and a new gasket to the turbocharger. Tighten the drain tube bolts to 24 Nꞏm (18 ft. lbs.)
torque.
NOTE: A new exhaust pipe to turbocharger elbow must be used. Do not reuse clamp.

10. Connect the exhaust pipe to the turbocharger and tighten the bolts to 11Nꞏm (100 ft. lbs.) torque.
11. Connect the wastegate command valve connector.
12. Lower the vehicle.
13.Pre-lube the turbocharger.Pour 50 to 60 cc (2 to 3 oz.) clean engine oil in the oil supply line fitting on the
turbo. Rotate the turbocharger impeller by hand to distrubute the oil thoroughly.
14. Install and tighten the oil supply line fitting nut to 24 Nꞏm (18 ft. lbs.) torque.
15. Position the charge air cooler inlet pipe to the turbocharger. With theclamp in position, tighten the clamp nut to
11 Nꞏm (95 in. lbs.) torque.
16. Position the air inlet hose to the turbocharger. Tighten the clamp to 4 Nꞏm (35 in. lbs.) torque.
17. Connect the battery negative cables.
18. Start the engine to check for leaks.

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.

CASE - FRONT
REMOVAL
1. Disconnect the 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. Remove viscous fan/drive/shroud assembly (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - REMOVAL).
8. Remove the accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
9. Remove the cooling fan support/hub from the front of the engine.
10. Raisethevehicleonhoist.
11. Remove the crankshaft damper (Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - REMOVAL) and
speed indicator ring.
12. Remove the lower fan shroud bracket.
13. Remove the upper fan shroud bracket that is mounted to the gear housing.
14. Lower the vehicle.
15. Remove the power steering pump.
16. Remove the accessory drive belt tensioner.
17. Remove the gear cover-to-housing bolts and gently pry the cover away from the housing, taking care not to mar
the gasket surfaces.
18. Remove the fuel injection pump (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL INJECTION PUMP -
REMOVAL).
19. Disconnect the camshaft position sensor connector.
20. Disconnect and remove engine speed sensor.
21. Remove the camshaft (Refer to 9 - ENGINE/ENGINE BLOCK/CAMSHAFT & BEARINGS (IN BLOCK) -
REMOVAL).
22. Remove the six front oil pan fasteners.
23. Remove the gear housing fasteners.
NOTE: Use care when removing the gear housing, to avoid damage to the oil pangasket, as the gasket will
be reused if it is not damaged.
24. Slide a feeler gauge between the gear housing and oil pan gasket, to break the gasket seal.
25. Remove the gear housing and gasket.
26. Clean the gasket material from the cylinder block and gear housing.

INSTALLATION
1.Inspectoilpangasket.Iftorn,gasketmustbe
replaced.
2. Install a new gear housing gasket onto cylinder
block and trim any excesss gasket material flush to
oil pan rail.
3. Place a small amount of mopar
engine RTV to the
corners of the block and pan gasket T-joint to
ensure a good seal.
4. Install the gear housing. Torque bolts to 24 Nꞏm (18
ft. lbs.).
5. If a new housing is installed, the camshaft position sensor, and engine speed sensor must be transferred to the
new housing.
6. Connect the camshaft position sensor connector.
7. Install and connect engine speed sensor.
8. Install the injection pump (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL INJECTION PUMP - INSTAL-
LATION).
9. Install the camshaft (Refer to 9 - ENGINE/ENGINE
BLOCK/CAMSHAFT & BEARINGS (IN BLOCK) -
INSTALLATION). Align the crankshaft and camshaft
gear marks as shown.
10. Install a new front crankshaft seal into the gear cover.
11. Apply a bead of Mopar
Silicone Rubber Adhesive Sealant or equivalent to the gear housing cover.Be sure to
surround all through holes.
12. Using the seal pilot to align the cover, install the cover to the housingand install the bolts. Tighten the bolts to
24 Nꞏm (18 ft. lbs.) torque.

13. Remove the seal pilot. Install front seal dust shield.
14. Raise the vehicle.
15. Install the crankshaft damper and speed indicator ring (Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - INSTALLATION). Torque bolts to 40 Nm (30 ft. lbs.), plus an additional 60°.
16. Install the lower fan shroud bracket. Torque bolts to 24 Nꞏm (18 ft. lbs.) torque.
17. Install the upper fan shroud brackets. Hand tighten only.
18. Lower vehicle.
19. Install the fan support/hub assembly and tighten bolts to 32 Nꞏm (24 ft.lbs.) torque.
20. Install the power steering pump.
21. Install the accessory drive belt tensioner. Torque bolt to 43 Nꞏm (32 ft. lbs.) torque.
22. Install the accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
23. Install the upper cooling fan/drive/shroud assembly (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - INSTAL-
LATION).
24. Torque the upper fan shroud brackets to 24 Nꞏm (18 ft. lbs.) torque.
25. Connect the coolant recovery bottle hose to the radiator filler neck.
26. Install the radiator upper hose and clamps.
27. Add engine oil.
28. Add coolant (Refer to 7 - COOLING - STANDARD PROCEDURE).
29. Connect the battery cables.
30. Start engine and inspect for leaks.

COVER - TIMING
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. Remove viscous fan/drive/shroud assembly (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - REMOVAL).
7. Remove the accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
8. Remove the cooling fan support/hub from the front of the engine.
9. Raise the vehicle on hoist.
10. Remove power steering pump.
11. Remove accessory drive belt tensioner.
12. Remove the crankshaft damper and speed indicator ring (Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL).
13. Lower the vehicle.
14. Remove the gear cover-to-housing bolts and gently pry the cover away from the housing, taking care not to mar
the gasket surfaces.
INSTALLATION
1. Install a new front crankshaft oil seal.
2. Obtain a seal pilot (1) installation tool from a crank-
shaft front seal service kit and install the pilot into
the seal.
3. Apply a bead of Mopar
Silicone Rubber Adhesive
Sealant or equivalent to the gear housing cover. Be
sure to surround all through holes.
4. Using the seal pilot to (1) align the cover , install
the cover to the housing and install the bolts.
Tighten the bolts to 24 Nꞏm (18 ft. lbs.) torque.
5. Remove the seal pilot. Install front seal dust shield.
6. Raise the vehicle.
7. Install the speed indicator ring and the crankshaft damper (Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - INSTALLATION).
8. Lower vehicle.
9. Install the fan support/hub assy, and tighten bolts to 32 Nꞏm (24 ft. lbs.) torque.
10. Install power steering pump.
11. Install accessory drive belt tensioner. Torque bolt to 43 Nꞏm (32 ft. lbs.) torque.
12. Install the accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
13. Install the cooling fan/drive/shroud assembly (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - INSTALLA-
TION).
14. Install the radiator upper hose and clamps.
15. Add coolant (Refer to 7 - COOLING - STANDARD PROCEDURE).
16. Connect the battery cables.
17. Start engine and inspect for leaks.

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ENGINE - 8.3L - SERVICE INFORMATION
DESCRIPTION ............................. 2713
DIAGNOSIS AND TESTING
INTRODUCTION . ......................... 2714
ENGINE DIAGNOSIS - PERFORMANCE .... 2715
ENGINE DIAGNOSIS - MECHANICAL ....... 2716
CYLINDER COMPRESSION PRESSURE
TEST.................................... 2718
CYLINDER COMBUSTION PRESSURE
LEAKAGE TEST.......................... 2718
CYLINDER HEAD GASKET FAILURE
DIAGNOSIS.............................. 2719
HYDRAULIC TAPPET NOISE DIAGNOSIS . . . 2720
ENGINE OIL LEAK INSPECTION ........... 2720
STANDARD PROCEDURE
ENGINE CORE AND OIL GALLERY PLUGS . 2722
FORM-IN-PLACE GASKETS AND SEALERS . 2722
ENGINE GASKET SURFACE
PREPARATION........................... 2723
HYDROSTATIC LOCKED ENGINE .......... 2723
REMOVAL - ENGINE ASSEMBLY . . ........... 2724
INSTALLATION - ENGINE ASSEMBLY ........ 2728
SPECIFICATIONS
ENGINE ................................. 2731
TORQUE ................................. 2736
SPECIAL TOOLS
ENGINE ................................. 2738
SYSTEM-AIR INTAKE
DESCRIPTION ............................. 2741
ELEMENT-AIR CLEANER
REMOVAL ................................. 2742
INSTALLATION ............................. 2743
HOUSING-AIR CLEANER
REMOVAL ................................. 2744
INSTALLATION ............................. 2745
MOUNTS-ENGINE
REMOVAL ................................. 2746
INSTALLATION ............................. 2747
MANIFOLD-INTAKE
DIAGNOSIS AND TESTING
INTAKE MANIFOLD LEAKS ................ 2748
REMOVAL ................................. 2748
INSPECTION ............................... 2750
INSTALLATION ............................. 2751
MANIFOLD-EXHAUST
REMOVAL ................................. 2754
INSPECTION ............................... 2755
INSTALLATION ............................. 2755
HEAD(S)-CYLINDER
REMOVAL - CYLINDER HEAD(S) ............. 2757CLEANING
CLEANING AND INSPECTION............. 2758
INSTALLATION - CYLINDER HEAD(S) ........ 2758
COVER(S)-CYLINDER HEAD
REMOVAL ................................. 2760
INSTALLATION ............................. 2761
ARMS-ROCKER
REMOVAL ................................. 2762
INSTALLATION ............................. 2762
SPRINGS/SEALS-VALVE
DIAGNOSIS AND TESTING
VALVE SPRING TESTING ................. 2763
STANDARD PROCEDURE - VALVE SPRING/
SEAL SERVICE IN-CAR ................... 2763
REMOVAL ................................. 2764
INSTALLATION ............................. 2765
INTAKE/EXHAUST - VALVES/SEATS/GUIDES
STANDARD PROCEDURE - VALVE AND
VALVE SEAT - REFACING ................. 2766
INSPECTION............................... 2767
COVER-TIMING CHAIN
REMOVAL ................................. 2769
INSTALLATION ............................. 2771
TIMING CHAIN AND SPROCKETS
REMOVAL ................................. 2774
INSTALLATION ............................. 2775
LUBRICATION
DESCRIPTION ............................. 2777
OPERATION ............................... 2777
DIAGNOSIS AND TESTING
CHECKING ENGINE OIL PRESSURE ....... 2777
ENGINE OIL LEAK ........................ 2777
OIL
STANDARD PROCEDURE
CHECKING ENGINE OIL LEVEL........... 2779
ENGINE OILAND FILTER CHANGE ........ 2779
COOLER & LINES-OIL
DESCRIPTION ............................. 2781
OPERATION ............................... 2781
STANDARD PROCEDURE - OIL COOLER LINE
QUICK CONNECT FITTING DISASSEMBLY/
ASSEMBLY............................... 2781
REMOVAL ................................. 2782
INSTALLATION ............................. 2783
PAN-OIL
REMOVAL ................................. 2784
INSTALLATION ............................. 2785
PUMP-OIL
REMOVAL ................................. 2788
DISASSEMBLY . ............................ 2788
CLEANING ................................. 2789