DODGE RAM SRT-10 2006 Service Repair Manual

STANDARD PROCEDURE
ENGINE CORE AND OIL GALLERY PLUGS
Using a blunt tool such as a drift (4) and a hammer,
strike the bottom edge of the cup plug. With the cup
plug rotated, grasp firmly with pliers (2) or other suit-
able tool and remove plug (5).
CAUTION: Do not drive cup plug into the casting
as restricted cooling can result and cause serious
engine problems.
Thoroughly clean inside of cup plug hole in cylinder
block or head. Be sure to remove old sealer. Lightly
coat inside of cup plug hole with Mopar
Stud and
Bearing Mount. Make certain the new plug is cleaned
of all oil or grease. Using proper drive plug, drive plug
into hole so that the sharp edge of the plug is at least
0.5 mm (0.020 in.) inside the lead-in chamfer.
It is not necessary to wait for curing of the sealant.
The cooling system can be refilled and the vehicle placed in service immediately.
FORM-IN-PLACE GASKETS AND SEALERS
There are numerous places where form-in-place gaskets are used on the engine. Care must be taken when apply-
ing form-in-place gaskets to assure obtaining the desired results.Do not use form-in-place gasket material
unless specified.Bead size, continuity, and location are of great importance. Too thin a bead can result in leakage
while too much can result in spill-overwhich can break off and obstruct fluid feed lines. A continuous bead of the
proper width is essential to obtain a leak-free gasket.
There are numerous types of form-in-place gasket materials that are used in the engine area. Mopar
Engine RTV
GEN II, Mopar
ATF-RTV, and MoparGasket Maker gasket materials, each have different properties and can not
be used in place of the other.
MOPAR
ENGINE RTV GEN II
Mopar
Engine RTV GEN II is used to seal components exposed to engine oil. This material is a specially designed
black silicone rubber RTV that retains adhesion and sealing properties when exposed to engine oil. Moisture in the
air causes the material to cure. This material is available in three ounce tubes and has a shelf life of one year. After
one year this material will not properly cure. Always inspect the package for the expiration date before use.
MOPAR
AT F R T V
Mopar
ATF RTV is a specifically designed black silicone rubber RTV that retains adhesion and sealing properties
to seal components exposed to automatic transmission fluid, engine coolants, and moisture. This material is avail-
able in three ounce tubes and has a shelf life of one year. After one year thismaterial will not properly cure. Always
inspect the package for the expiration date before use.
MOPAR
GASKET MAKER
Mopar
Gasket Maker is an anaerobic type gasket material. The material cures in the absence of air when
squeezed between two metallic surfaces. It will not cure if left in the uncovered tube. The anaerobic material is for
use between two machined surfaces. Do not use on flexible metal flanges.
MOPAR
BED PLATE SEALANT
Mopar
Bed Plate Sealant is a unique (green-in-color) anaerobic type gasket material that is specially made to seal
the area between the bedplate and cylinder block without disturbing the bearing clearance or alignment of these
components. The material cures slowly in the absence of air when torqued between two metallic surfaces, and will
rapidly cure when heat is applied.
MOPAR
GASKET SEALANT
Mopar
Gasket Sealant is a slow drying, permanently soft sealer. This material isrecommended for sealing
threaded fittings and gaskets against leakage of oil and coolant. Can be used on threaded and machined parts
under all temperatures. This material is used on engines with multi-layersteel (MLS) cylinder head gaskets. This

material also will prevent corrosion. MoparGasket Sealant is available in a 13 oz. aerosol can or 4 oz./16 oz. can
w/applicator.
FORM-IN-PLACE GASKET AND SEALER APPLICATION
MoparGasket Maker material should be applied sparingly 1 mm (0.040 in.) diameter or less of sealant to one
gasket surface. Be certain the material surrounds each mounting hole. Excess material can easily be wiped off.
Components should be torqued in place within 15 minutes. The use of a locating dowel is recommended during
assembly to prevent smearing material off the location.
Mopar
Engine RTV GEN II or ATF RTV gasket material should be applied in a continuous bead approximately 3
mm (0.120 in.) in diameter. All mounting holes must be circled. For corner sealing,a3.17mmor6.35mm(1/8in.
or 1/4 in.) drop is placed in the center of the gasket contact area. Uncured sealant may be removed with a shop
towel. Components should be torqued in place while the sealant is still wettothetouch(within10minutes).The
usage of a locating dowel is recommended during assembly to prevent smearing material off the location.
Mopar
Gasket Sealant in an aerosol can should be applied using a thin, even coat sprayed completely over both
surfaces to be joined, and both sides of a gasket. Then proceed with assembly. Material in a can w/applicator can
be brushed on evenly over the sealing surfaces. Material in an aerosol can shouldbeusedonengineswithmulti-
layer steel gaskets.
ENGINE GASKET SURFACE PREPARATION
To ensure engine gasket sealing, proper surface prep-
aration must be performed, especially with the use of
aluminum engine components and multi-layer steel
cylinder head gaskets.
Neveruse the following to clean gasket surfaces:
Metal scraper
Abrasive pad or paper to clean cylinder block
and head
High speed power tool with an abrasive pad or a
wire brush (1)
NOTE: Multi-Layer Steel (MLS) head gaskets
require a scratch free sealing surface.
Only use the following for cleaning gasket surfaces:
Solvent or a commercially available gasket
remover
Plastic or wood scraper (3)
Drill motor with 3M Roloc™ Bristle Disc (white or yellow) (2)
CAUTION: Excessive pressure or high RPM (beyond the recommended speed), can damage the sealing sur-
faces. The mild (white, 120 grit) bristle disc is recommended. If necessary, the medium (yellow, 80 grit) bris-
tle disc may be used on cast iron surfaces with care.
HYDROSTATIC LOCKED ENGINE
When an engine is suspected to be hydrostatically locked, regardless of what caused the problem, the following
steps should be used.
CAUTION: DO NOT use starter motor to rotate the engine, severe damage may occur.
1. Inspect air cleaner, induction system and intake manifold to ensure system is dry and clear of foreign material.
2. Remove negative battery cable.
3. Place a shop towel around the spark plugs when removing them from the engine. This will catch any fluid that
may possibly be in the cylinder under pressure.
4. With all spark plugs removed, rotate engine crankshaft using a breaker bar and socket.

5. Identify the fluid in the cylinder(s) (i.e., coolant, fuel, oil or other).
6. Make sure all fluid has been removed from the cylinders. Inspect engine for damage (i.e., connecting rods, pis-
tons, valves, etc.)
7. Repair engine or components as necessary to prevent this problem from re-occurring.
CAUTION: Squirt approximately one teaspoon of oil into the cylinders, rotateenginetolubricatethecylin-
der walls to prevent damage on restart.
8. Install new spark plugs.
9. Drain engine oil and remove oil filter.
10. Fill engine with specified amount of approved oil and install new oil filter.
11. Connect negative battery cable.
12. Start engine and check for any leaks.
REMOVAL - ENGINE ASSEMBLY
1. Perform fuel pressure release procedure (Refer to
14 - FUEL SYSTEM/FUEL DELIVERY - STAN-
DARD PROCEDURE).
2. Disconnect negative battery cable.
3. Disconnect throttle body air inlet duct, remove air
cleaner cover (Refer to 9 - ENGINE/AIR INTAKE
SYSTEM/AIR CLEANER ELEMENT - REMOVAL).
4. Raise and support the vehicle.
5. Remove the lower engine shield.
6. Drain cooling system (Refer to 7 - COOLING/EN-
GINE - STANDARD PROCEDURE - DRAINING
COOLING SYSTEM).
7. Paint mark and remove the driveshaft (Refer to 3 -
DIFFERENTIAL & DRIVELINE/PROPELLER
SHAFT/PROPELLER SHAFT - REMOVAL).
8.Removethetransmission(Referto21-TRANS-
MISSION/TRANSAXLE/MANUAL - REMOVAL).
9. Remove the starter (Refer to 8 - ELECTRICAL/
STARTING/STARTER MOTOR - REMOVAL).
10. Disconnect the front exhaust pipe flange to
exhaust manifold fasteners (1 and 2).
11. Disconnect the hydraulic cooling fan lines and capture any spillage (Refer to 7 - COOLING/ENGINE/RADIATOR
FA N - R E M O VA L ) .
12. Drain engine oil and remove the oil filter.
13. Separate the air conditioning hose from the fan shroud.
14. Disconnect the lower radiator hose.
15. Disconnect the power steering line support bracket at the lower left ofthe radiator.
16. Loosen both engine mount through bolts.

17. Separate the ground strap (1) from the floor
board, above the right exhaust flange.
18. Lower the vehicle.
19. Discharge air conditioning system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/RE-
FRIGERANT - STANDARD PROCEDURE).
20. Remove the upper radiator hose.
21. Disconnect windshield washer hose at the splice.
22. Remove radiator core support.
23. Disconnect the cooling fan harness connector
(Refer to 7 - COOLING/ENGINE/RADIATOR FAN
- REMOVAL).
24. Remove the radiator and radiator fan assembly
(Refer to 7 - COOLING/ENGINE/RADIATOR -
REMOVAL).
25. Remove the A/C condenser, cap and position the
hoses aside.
26. Disconnect the heater hoses at the top front cover
and at the lower coolant housing and position
aside.
27. Disconnect the oil cooler hoses from the engine
and position aside (Refer to 9 - ENGINE/LUBRI-
CATION/OIL COOLER & LINES - STANDARD
PROCEDURE).
28. Remove accessory drive belt (1).
29. Disconnect and remove generator.
30. Remove power steering pump mounting bolts and
set pump aside.

31. Disconnect A/C lines and electrical connector from
A/C compressor. Plug holes in A/C compressor to
prevent debris from entering A/C compressor.
32. Disconnect brake booster vacuum hose and fuel
line to fuel rail.
33. Disconnect the cruise control, accelerator cable
and fuel vapor purge harness (2) , then set aside.
34. Disconnect the engine harness connectors on top
of the intake manifold.
35. Disconnect the spark plug wires from the spark
plugs and set the plug wires on top of the engine.
36. Disconnect the ground strap at the thermostat
housing and pull the electrical harness under-
neath the intake manifold and set aside.

37. Install Special Tool 9363 - Engine Lifting Brackets
(1) and to the exhaust manifold heat shield studs
where indicated.
38. Insert engine lifting bar (1) through the access
holes in the engine lifting brackets (2) and secure
with the bar retaining pins (3).

39. Remove engine with an engine hoist (1).
INSTALLATION - ENGINE ASSEMBLY
1. Attach engine hoist (1) and lower the engine into
engine compartment, aligning the left and right
engine mounts
2. Install left and right engine mount insulator bolts
and nuts. Tighten nuts to 102 Nꞏm (75 ft. lbs.).
3. Remove engine hoist and engine lifting bar (2) and
brackets (3).

4. Install the exhaust manifold heat shield nuts (2)
and tighten to 6 Nꞏm (50 in. lbs.).
5. Connect the ground strap to the thermostat hous-
ing and route the electrical and purge harness
underneath the throttle body and attach the con-
nectors.
6. Connect the fuel vapor purge lines.
7. Properly route and connect the spark plug wires.
8. Connect the engine electrical harnesses.
9. Connect the brake booster vacuum hose, fuel line,
cruise control and accelerator cables.
10. Install the A/C lines at the A/C compressor (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING/A/C COMPRESSOR - REMOVAL).
11. Connect A/C clutch electrical connector (Refer to
24 - HEATING & AIR CONDITIONING/PLUMB-
ING/A/C COMPRESSOR - REMOVAL).
12. Install the power steering pump.
13. Install the generator.
14. Install the accessory drive belt.
15. Connect the heater hoses to the engine.
16. Install the radiator and cooling fan assembly.
17. Install the A/C condenser.
18. Connect the A/C lines to the condenser.
19. Connect the cooling fan electrical connector.
20. Connect the windshield washer hose at the splice.
21. Install the coolant recovery container.
22. Install the upper radiator hose.
23. Install the throttle body air inlet duct and the air
cleaner element cover.
24. Raise and support the vehicle.
25. Install transmission.
26. Install transmission bolts and tighten bolts to:
7/16 Transmission bolts and washers (2) - 68
Nꞏm (50 ft. lbs.)
Transmission to top of engine - 41 Nꞏm (30 ft.
lbs.)
Transmission to oil pan (3) - 30 Nꞏm (22 ft. lbs.)
27. Install drive shaft.

28. Install the ground strap (1) to the floor pan above
the right exhaust manifold flange.
29. Connect the front exhaust pipes to the exhaust
manifolds and tighten the fasteners (1 and 2) to
34 Nꞏm (25 ft. lbs.).

30. Connect oil cooler lines (4) and connect the oil
pressure sensor (1) and oil temperature sensor
(5).
31. Install the power steering line support bracket at
the radiator.
32. Install lower radiator hose.
33. Connect the cooling fan hydraulic lines (Refer to 7
- COOLING/ENGINE/RADIATOR FAN - INSTAL-
LATION).
34. Connect the A/C line to the fan shroud.
35. Install under body shield.
36. Lower vehicle.
37. Fill engine crankcase with the proper oil to the
correct level (Refer to LUBRICATION & MAINTE-
NANCE/FLUID TYPES - SPECIFICATIONS).
38. Evacuate and recharge the air conditioning (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING - STANDARD PROCEDURE).
39. Fill the cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
40. Fill power steering to proper leveland purge the system (Refer to 19 - STEERING/PUMP - STANDARD PRO-
CEDURE).
41. Connect the negative battery cable.
42. Start the engine and run until operating temperature is obtained.
43. Turn engine off and inspect for leaks.
44. Recheck all fluid levels, fill as required.
SPECIFICATIONS
ENGINE
GENERAL SPECIFICATIONS
DESCRIPTION SPECIFICATION
Ty pe 9 0° V-1 0
Number of Cylinders 10
Firing Order 1-10-9-4-3-6-5-8-7-2
Compression Ratio 9.6:1
Brake Horsepower 501@5600 RPM
Torque 525 ft. lbs. @4100 RPM
Crankshaft Forged Steel
Cylinder Block Aluminum Alloy with Interference Fit Cast Iron Liners
Connecting Rods Cracked Cap Powdered Metal
Pistons Cast Aluminum Alloy
Metric Standard
Displacement 8.3L 505 cu. in.
Bore 102.4 mm 4.03 in.
Stroke 100.6 mm 3.96 in.
Compression Pressure 1069-1172 kPa 155-170 psi
Engine Weight (Approx.) 284 Kilograms 625 Lbs.