torque DODGE RAM SRT-10 2006 Service Owners Manual

MANIFOLD - EXHAUST
DESCRIPTION
The exhaust manifolds are log style with a patented flow enhancing design to maximize performance. The exhaust
manifolds are made of high silicon molybdenum cast iron. A perforated coregraphite exhaust manifold gasket is
used to improve sealing to the cylinder head. The exhaust manifolds are covered by a three layer laminated heat
shield for thermal protection and noise reduction. The heat shields are fastened with a torque prevailing nut that is
backed off slightly to allow for the thermal expansion of the exhaust manifold.
REMOVAL
RIGHT EXHAUST MANIFOLD
1. Disconnect negative cable for battery.
2. Remove air cleaner assembly, resonator assembly and air inlet hose.
3. Remove accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
4. Remove A/C compressor (Refer to 24 -HEATING & AIR CONDITIONING/PLUMBING/A/C COMPRESSOR -
REMOVAL).
5. Remove A/C accumulator support bracket fastener.
6. Drain coolant below heater hose level (Refer to 7 - COOLING - STANDARD PROCEDURE).
7. Remove heater hoses at engine.
8. Remove fasteners(4,5) attaching exhaust manifold heat shield.
9. Remove heat shield.

CAUTION: Remove excess oil from camshaft
sprocket retaining bolt before reinstalling bolt.
Failure to do so may cause over-torqueing of bolt
resulting in bolt failure.
6. Position the camshaft drive gear onto the camshaft,
remove oil from bolt then install the retaining bolt.
Using Special Tools, Spanner Wrench 6958 with
Adapter Pins 8346 and a suitable torque wrench
(1), Tighten retaining bolt to 122 Nꞏm (90 ft. Lbs.).
7. Remove special tool 8350 (3,4).

INSTALLATION
1. Using a vise, lightly compress the secondary chain
tensioner piston until the piston step is flush with
the tensioner body. Using a pin or suitable tool,
release ratchet pawl by pulling pawl back against
spring force through access hole on side of ten-
sioner. While continuing to hold pawl back, Push
ratchet device to approximately 2 mm from the ten-
sioner body. Install Special Tool 8514 lock pin (3)
into hole on front of tensioner (2). Slowly open vise
to transfer piston spring force to lock pin.
2. Position primary chain tensioner over oil pump and insert bolts into lower two holes on tensioner bracket. Tighten
bolts to 28 Nꞏm (250 in. lbs.).
CAUTION: Overtightening the tensioner arm torx
bolt can cause severe damage to the cylinder head.
Tighten torx
bolt to specified torque only.
3. Install right side chain tensioner arm. Apply Mopar
Lock N, Seal to torxbolt, tighten bolt to 17 Nꞏm (150 in.
lbs.).
NOTE: The silver bolts retain the guides to the cylinder heads and the blackbolts retain the guides to the
engine block.
4. Install the left side chain guide. Tighten the bolts to 28 Nꞏm (250 in. lbs.).
CAUTION: Overtightening the tensioner arm torx
bolt can cause severe damage to the cylinder head.
Tighten torx
bolt to specified torque only.
5. Install left side chain tensioner arm. Apply Mopar
Lock N, Seal to torxbolt, tighten bolt to 17 Nꞏm (150 in. lbs.).
6. Install the right side chain guide. Tighten the bolts to 28 Nꞏm (250 in. lbs.).

7. Install both secondary chains onto the idler
sprocket. Align two plated links on the secondary
chains to be visible through the two lower openings
on the idler sprocket (4 o’clock and 8 o’clock).
Once the secondary timing chains are installed,
position special tool 8515 (6) to hold chains in
place for installation.
8. Align primary chain double plated links with the tim-
ingmarkat12o’clock(1)ontheidlersprocket.
Align the primary chain single plated link with the
timing mark at 6 o’clock on the crankshaft sprocket
(3).
9. Lubricate idler shaft and bushings with clean
engine oil.
10. Install all chains, crankshaft sprocket, and idler
sprocket as an assembly. After guiding both sec-
ondary chains through the block and cylinder
head openings, affix chains with a elastic strap or
the equivalent, This will maintain tension on
chains to aid in installation.
NOTE: It will be necessary to slightly rotate cam-
shafts for sprocket installation.
11. Align left camshaft sprocket “L” dot to plated link
on chain.
12. Align right camshaft sprocket “R” dot to plated link
on chain.
CAUTION: Remove excess oil from the camshaft
sprocket bolt. Failure to do so can result in over-
torque of bolt resulting in bolt failure.
13. Remove Special Tool 8515, then attach both sprockets to camshafts. Remove excess oil from bolts, then Install
sprocket bolts, but do not tighten at this time.
14. Verify that all plated links are aligned with the marks on all sprocketsand the “V8” marks on camshaft sprockets
are at the 12 o’clock position.
CAUTION: Ensure the plate between the left secondary chain tensioner and block is correctly installed.
15. Install both secondary chain tensioners. Tighten bolts to 28 Nꞏm (250 in. lbs.).
NOTE: Left and right secondary chain tensioners are not common.
16. Before installing idler sprocketbolt, lubricate washer with oil, andtighten idler sprocket assembly retaining bolt
to 34 Nꞏm (25 ft. lbs.).
17. Remove all locking pins from tensioners.
CAUTION: After pulling locking pins out of each tensioner, DO NOT manuallyextend the tensioner(s)
ratchet. Doing so will over tension thechains, resulting in noise and/or high timing chain loads.

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ENGINE - 5.7L - SERVICE INFORMATION
DESCRIPTION ............................. 2449
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION............. 2449
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - PERFORMANCE............. 2449
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - MECHANICAL............... 2451
DIAGNOSIS AND TESTING - CYLINDER
COMPRESSION PRESSURE............... 2451
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE...... 2452
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - LUBRICATION............... 2453
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - MECHANICAL............... 2453
STANDARD PROCEDURE
STANDARD PROCEDURE - REPAIR
DAMAGED OR WORN THREADS.......... 2456
STANDARD PROCEDURE—HYDROSTATIC
LOCK.................................... 2456
REMOVAL ................................. 2457
INSTALLATION ............................. 2462
SPECIFICATIONS
5.7L ENGINE ............................. 2467
TORQUE ................................. 2472
SPECIAL TOOLS
5.7L ENGINE ............................. 2475
ELEMENT - AIR CLEANER
REMOVAL ................................. 2478
INSTALLATION ............................. 2479
CYLINDER HEAD
OPERATION—CYLINDER HEAD ............. 2481
DIAGNOSIS AND TESTING—CYLINDER HEAD
GASKET FAILURE........................ 2481
REMOVAL ................................. 2482
CLEANING ................................. 2484
INSPECTION ............................... 2484
INSTALLATION ............................. 2485
COVER - CYLINDER HEAD
REMOVAL ................................. 2490
INSTALLATION ............................. 2493
VALVES & SEATS - INTAKE/EXHAUST
DESCRIPTION
DESCRIPTION - VALVE GUIDES ........... 2496
DESCRIPTION ........................... 2496
STANDARD PROCEDURE - REFACING ....... 2496
REMOVAL ................................. 2497
INSTALLATION ............................. 2497ROCKER ARM
REMOVAL ................................. 2498
INSTALLATION ............................. 2500
SEALS - VALVE GUIDE
DESCRIPTION ............................. 2503
SPRINGS - VALVE
REMOVAL ................................. 2504
INSTALLATION ............................. 2510
ENGINE BLOCK
CLEANING ................................. 2515
INSPECTION............................... 2515
CAMSHAFT
REMOVAL
REMOVAL - CAMSHAFT CORE HOLE PLUG . 2516
REMOVAL - CAMSHAFT ................... 2516
INSPECTION............................... 2520
INSTALLATION
INSTALLATION - CAMSHAFT CORE HOLE
PLUG.................................... 2520
INSTALLATION - CAMSHAFT .............. 2521
CRANKSHAFT
REMOVAL ................................. 2527
INSTALLATION ............................. 2531
BEARINGS - CRANKSHAFT MAIN
STANDARD PROCEDURE - CRANKSHAFT
MAIN BEARING - FITTING ................. 2536
INSPECTION............................... 2536
SEAL - CRANKSHAFT OIL - FRONT
REMOVAL ................................. 2537
INSTALLATION ............................. 2538
SEAL - CRANKSHAFT OIL - REAR
DIAGNOSIS AND TESTING - REAR SEAL
AREA LEAKS . ............................ 2539
REMOVAL ................................. 2539
INSTALLATION ............................. 2540
RETAINER - CRANK REAR OIL - SEAL
REMOVAL ................................. 2541
INSTALLATION ............................. 2541
FLEX PLATE
REMOVAL ................................. 2542
INSTALLATION ............................. 2542
TAPPETS - HYDRAULIC ROLLER
DIAGNOSIS AND TESTING - HYDRAULIC
TAPPETS ................................ 2543
REMOVAL ................................. 2543
INSTALLATION ............................. 2544
PISTON & CONNECTING ROD
DESCRIPTION ............................. 2546
STANDARD PROCEDURE - PISTON FITTING . 2546
REMOVAL ................................. 2547
CLEANING ................................. 2548

DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL
CONDITION POSSIBLE CAUSES CORRECTIONS
NOISY VALVES 1. High or low oil level in
crankcase.1. (Refer to LUBRICATION &
MAINTENANCE -
SPECIFICATIONS)
2. Thin or diluted oil. 2. Change oil and filter.
3. Low oil pressure. 3. Check oil pump, if Ok, check rod
and main bearings for excessive
wear.
4. Dirt in lash adjusters. 4. Replace as necessary.
5. Worn rocker arms. 5. Replace as necessary.
6. Worn lash adjusters 6. Replace as necessary.
7. Worn valve guides. 7. (Refer to 9 - ENGINE/CYLINDER
HEAD/INTAKE/EXHAUST VALVES
& SEATS - STANDARD
PROCEDURE)
8. Excessive runout of valve seats
on valve faces.8. (Refer to 9 - ENGINE/CYLINDER
HEAD/INTAKE/EXHAUST VALVES
& SEATS - STANDARD
PROCEDURE)
CONNECTING ROD NOISE 1. Insufficient oil supply. 1. (Refer to LUBRICATION&
MAINTENANCE -
SPECIFICATIONS)
2. Low oil pressure. 2. Check oil pump, if Ok, check rod
and main bearings for excessive
wear.
3. Thin or diluted oil. 3. Change oil and filter.
4. Excessive bearing clearance. 4. Replace as necessary.
5. Connecting rod journal
out-of-round.5. Service or replace crankshaft.
6. Misaligned connecting rods. 6. Replace bent connecting rods.
MAIN BEARING NOISE 1. Insufficient oil supply. 1. (Refer to LUBRICATION &
MAINTENANCE -
SPECIFICATIONS)
2. Low oil pressure. 2. Check oil pump, if Ok, check rod
and main bearings for excessive
wear.
3. Thin or diluted oil. 3. Change oil and filter.
4. Excessive bearing clearance. 4. Replace as necessary.
5. Excessive end play. 5. Check thrust washers for wear.
6. Crankshaft journal out-of round. 6. Service or replace crankshaft.
7. Loose flywheel or torque
converter.7. Tighten to correct torque
DIAGNOSIS AND TESTING - CYLINDER COMPRESSION PRESSURE
The results of a cylinder compressionpressure test can be utilized to diagnose several engine malfunctions.

CONDITION POSSIBLE CAUSES CORRECTION
MAIN BEARING NOISE 1. Insufficient oil supply 1. Check engine oil level.
2. Low oil pressure 2. Check engine oil level. If ok,
Perform oil pressure test. (Refer to
9 - ENGINE/LUBRICATION -
DIAGNOSIS AND TESTING)
3. Thin or diluted oil 3. Change oil to correct viscosity.
4. Excessive main bearing
clearance4. Measure bearings for correct
clearance. Repair as necessary
5. Excessive end play 5. Check crankshaft thrust bearing
for excessive wear on flanges
6. Crankshaft main journal out of
round or worn6. Grind journals or replace
crankshaft
7. Loose flywheel or torque
converter7. Inspect crankshaft, flexplate/
flywheel and bolts for damage.
Tighten to correct torque
LOW OIL PRESSURE 1. Low oil level 1. Check oil level and fill if
necessary
2. Faulty oil pressure sending unit 2. Install new sending unit
3. Clogged oil filter 3. Install new oil filter
4. Worn oil pump 4. Replace oil pump assembly.
5. Thin or diluted oil 5. Change oil to correct viscosity.
6. Excessive bearing clearance 6. Measure bearings for correct
clearance
7. Oil pump relief valve stuck 7. Remove valve to inspect, clean
and reinstall
8. Oil pickup tube loose, broken,
bent or clogged8. Inspect oil pickup tube and pump,
and clean or replace if necessary
9. Oil pump cover warped or
cracked9. Install new oil pump
OIL LEAKS 1. Misaligned or deteriorated
gaskets1. Replace gasket
2. Loose fastener, broken or porous
metal part2. Tighten, repair or replace the part
3. Front or rear crankshaft oil seal
leaking3. Replace seal
4. Leaking oil gallery plug or cup
plug4. Remove and reseal threaded
plug. Replace cup style plug

CONDITION POSSIBLE CAUSES CORRECTION
EXCESSIVE OIL CONSUMPTION
OR SPARK PLUGS OIL FOULED1. CCV System malfunction 1. (Refer to 25 - EMISSIONS
CONTROL/EVAPORATIVE
EMISSIONS - DESCRIPTION) for
correct operation
2. Defective valve stem seal(s) 2. Repair or replace seal(s)
3. Worn or broken piston rings 3. Hone cylinder bores. Install new
rings
4. Scuffed pistons/cylinder walls 4. Hone cylinder bores and replace
pistons as required
5. Carbon in oil control ring groove 5. Remove rings and de-carbon
piston
6. Worn valve guides 6. Inspect/replace valve guides as
necessary
7. Piston rings fitted too tightly in
grooves7. Remove rings and check ring end
gap and side clearance. Replace if
necessary
STANDARD PROCEDURE
STANDARD PROCEDURE - REPAIR DAMAGED OR WORN THREADS
CAUTION: Be sure that the tapped holes maintain the original center line.
Damaged or worn threads can be repaired. Essentially, this repair consistsof:
Drilling out worn or damaged threads.
Tapping the hole with a special Heli-Coil Tap, or equivalent.
Installing an insert into the tapped hole to bring the hole back to its original thread size.
STANDARD PROCEDURE—HYDROSTATIC LOCK
CAUTION: DO NOT use the starter motor to rotate the crankshaft. Severe damage could occur.
When an engine is suspected of hydrostatic lock (regardless of what causedthe problem), follow the steps below.
1. Perform the Fuel Pressure Release Procedure (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY - STANDARD
PROCEDURE).
2. Disconnect the negative cable(s) from the battery.
3. Inspect air cleaner, induction system, and intake manifold to ensure system is dry and clear of foreign material.
4. Place a shop towel around the spark plugs to catch any fluid that may possibly be under pressure in the cylinder
head. Remove the spark plugs.
5. With all spark plugs removed, rotate the crankshaft using a breaker bar and socket.
6. Identify the fluid in the cylinders (coolant, fuel, oil, etc.).
7. Be sure all fluid has been removed from the cylinders.
8. Repair engine or components as necessary to prevent this problem from occurring again.
9. Squirt a small amount of engine oil into the cylinders to lubricate the walls. This will prevent damage on restart.
10. Install new spark plugs. Tighten the spark plugs to 41 Nꞏm (30 ft. lbs.) torque.
11. Drain engine oil. Remove and discard the oil filter.
12. Install the drain plug. Tighten the plug to 34 Nꞏm (25 ft. lbs.) torque.
13. Install a new oil filter.
14. Fill engine crankcase with the specified amount and grade of oil. (Refer to LUBRICATION & MAINTENANCE -
SPECIFICATIONS).

7. Tighten engine mount through bolts.
8. Install drive plate to torque converter bolts. (Auto-
matic transmission models)
9. Install the structural dust cover (1) and transmis-
sion dust cover, (Refer to 9 - ENGINE/ENGINE
BLOCK/STRUCTURAL COVER - INSTALLATION) .
10. Install the starter (1) and connect the starter wires
(Refer to 8 - ELECTRICAL/STARTING/STARTER
MOTOR - INSTALLATION).

SPECIFICATION SPECIFICATION
At Curb Idle Speed (MIN)* 25 kPa (4 psi)
@ 3000 rpm 170 - 758 kPa (25 - 110 psi)
* CAUTION: If pressure is zero at curb idle, DO NOT run engine
TORQUE
TORQUE CHART 5.7L ENGINE
DESCRIPTION Nꞏm Ft. In.
Lbs. Lbs.
Block Pipe Plugs
(1/4 NPT)20 — 177
(3/8 NPT) 27 — 240
Camshaft Sprocket—Bolt 122 90 —
Camshaft Tensioner Plate—Bolts 28 — 250
Coil to Cylinder Head Cover—Bolts 7 — 62
Timing Chain Case Cover—Bolts 28 — 250
Lifting Stud 55 40 —
Connecting Rod Cap—Bolts 21
plus 90° Turn15
plus 90° Turn—
Main Bearing Cap—Bolts
M-1227
plus 90° Turn——
Crossbolts
M-828 — —
Cylinder Head—Bolts
M-12 Bolts
Step 1 34 25 —
Step 2 54 40 —
Step 3 Turn 90° Turn 90° —
M-8 Bolts —
Step 1 20 15 —
Step 2 34 25 —
Cylinder Head Cover—Bolts 8 — 70
Exhaust Manifold to Cylinder Head 25 — 220
Flexplate to Crankshaft—Bolts 95 70 —
Flywheel to Crankshaft—Bolts 75 55 —
Front Insulator—Thru bolt/nut 95 70 —
Front Insulator to Support Bracket
—Stud Nut (4WD) 41 30 —
—Through Bolt/Nut (4WD) 102 75 —
Front Insulator to Block—Bolts (2WD) 95 70 —
Generator—Mounting Bolt 55 40 —
Intake Manifold—Bolts Refer to Procedure
Lifter Guide Holder 12 — 106
Oil Pan Bolts 12 — 105
Oil Dipstick Tube 12 — 105