belt DODGE RAM SRT-10 2006 Service Repair Manual

DAMPER - CRANKSHAFT
REMOVAL
1. Remove the accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
2. Remove the four (4) damper to crankshaft bolts and remove damper and speed indicator ring.
INSPECTION
1. Inspect the damper hub for cracks and replace if
any are found.
2. Inspect the rubber member for deterioration or
missing segments.
3. Inspect the index lines (1) on the damper hub (2)
and the inertia member (3). If the lines are more
than 1.59 mm (1/16 in.) out of alignment, replace
the damper.
INSTALLATION
1. Install speed indicator ring.
NOTE: The speed indicator ring is located over a dowel pin.
2. Install the crankshaft damper and bolts. Tighten bolts to 40 Nꞏm (30 ft. lbs.) torque, plus an additional 60°.
NOTE: The damper must be installed so the hole is located over the dowel pin.
3. Install the accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).

PUMP - ENGINE OIL
REMOVAL
1. Disconnect the battery negative cables.
2. Remove fan/drive assembly (Refer to 7 - COOL-
ING/ENGINE/RADIATOR FAN - REMOVAL).
3. Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
4. Remove the fan support/hub assembly.
5. Remove crankshaft damper (Refer to 9 - ENGINE/
ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL) and speed indicator ring.
6. Remove power steering pump.
7. Remove accessory drive belt tensioner.
8. Remove the gear housing cover (Refer to 9 -
ENGINE/VALVE TIMING/GEAR HOUSING COVER
- REMOVAL).
9. Remove the four mounting bolts (2) and pull the oil pump (1) from the bore in the cylinder block.
CLEANING
Clean all parts in solvent and dry with compressed air. Clean the old sealerresidue from the back of the gear
housing cover and front of the gear housing.
INSPECTION
Disassemble and inspect the oil pump as follows:
1. Visually inspect the lube pump gears for chips,
cracks or excessive wear.
2. Remove the back plate (1).
3. Mark TOP on the gerotor planetary (3) using a felt
tip pen.
4. Remove the gerotor planetary (3) inspect for
excessive wear or damage. Inspect the pump
housing and gerotor drive (2) for damaged and
excessive wear.
5. Install the gerotor planetary in the original position.
6. Measure the tip clearance (1). Maximum clearance
is 0.1778 mm (0.007 inch). If the oil pump is out of
limits, replace the pump.

3. The back plate on the pump seats against the bot-
tom of the bore in the cylinder block. When the
pump is correctly installed, the flange on the pump
will not touch the cylinder block.
4. Measure the idler gear to pump drive gear back-
lash and the idler gear to crankshaft gear backlash.
The backlash should be 0.15- 0.25 mm
(0.006-0.010 inch). If the backlash is out of limits,
replace the oil pump.
5. If the adjoining gear moves when you measure the
backlash, the reading will be incorrect.
6. Apply a bead of Mopar
Silicone Rubber Adhesive Sealant or equivalent to the gear housing cover sealing sur-
face.
7. Install the gear housing cover (Refer to 9 - ENGINE/VALVE TIMING/GEAR HOUSING COVER - INSTALLA-
TION).
8. Install the vibration damper (Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION) and
speed indicator ring.
9. Install the fan support/hub assemblyRefer to (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - INSTALLA-
TION)
10. Install power steering pump.
11. Install accessory drive belt tensioner. Torque bolt to 43 Nꞏm (32 ft. lbs.).
12. Install the accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
13. Install the cooling fan (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - INSTALLATION).
14. Connect battery negative cables.
15. Start engine and check for oil leaks.

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.

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.

ENGINE DIAGNOSIS - PERFORMANCE
CONDITION POSSIBLE CAUSES CORRECTION
ENGINE WILL NOT
CRANK1. Weak or discharged battery. 1. Charge or replace battery as necessary.
(Refer to 8 - ELECTRICAL/BATTERY
SYSTEM - DIAGNOSIS AND TESTING).
Check charging system. Refer to the
appropriate Diagnostic Information for
charging system diagnosis.
2. Corroded or loose battery
connections.2. Clean/tighten battery/starter connections.
3. Faulty starter or related circuits. 3. Check starting system. (Refer to8-
ELECTRICAL/STARTING - DIAGNOSIS
AND TESTING).
4. Seized accessory drive
component.4. Remove accessory drive belt and
attempt to start engine. If engine cranks,
repair/replace seized component.
5. Engine internal mechanical failure
or hydrostatic lock.5. (Refer to 9 - ENGINE - STANDARD
PROCEDURE - HYDROSTATIC LOCKED
ENGINE).
ENGINE CRANKS BUT
WILL NOT START1. No spark. 1. Check for spark. Refer to the appropriate
Diagnostic Information for ignition system
diagnosis.
2. No fuel. 2. Perform fuel pressure test. Refer to the
appropriate Diagnostic Information for fuel
system diagnosis.
3. Low or no engine compression. 3. Perform cylinder compression test.
(Refer to 9 - ENGINE - DIAGNOSIS AND
TESTING - CYLINDER COMPRESSION
PRESSURE TEST).
ENGINE LOSS OF
POWER1. Worn or incorrect gapped spark
plugs.1. Replace spark plugs or set gap.
2. Dirt or water in fuel system. 2. Clean system and replace fuel filter.
3. Faulty fuel pump. 3. Replace fuel pump.
4. Incorrect valve timing. 4. Correct valve timing.
5. Blown cylinder head gasket(s). 5. Replace cylinder head gasket(s).
6. Low compression. 6. Test cylinder compression. (Refer to 9 -
ENGINE - DIAGNOSIS AND TESTING -
CYLINDER COMPRESSION PRESSURE
TEST)
7. Burned, warped, or pitted valves. 7. Install new or reface valves as
necessary.
8. Plugged or restricted exhaust. 8. Replace parts as necessary.
9. Faulty ignition cables. 9. Replace ignition cables as necessary.
10. Faulty coil(s). 10. Test and replace as necessary.

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.

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.

MANIFOLD-INTAKE
DIAGNOSIS AND TESTING
INTAKE MANIFOLD LEAKS
An intake manifold air leak is characterized by lower than normal manifoldvacuum, rough idle, or engine misfire.
WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO NOT STAND IN ADIRECT LINE
WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE PULLEYS, BELT OR THE FAN. DO NOT WEAR
LOOSE CLOTHING.
1. Start the engine.
2. Spray a small stream of water (Spray Bottle) at the suspected leak area.
3. If engine RPM’S change, the area of the suspected leak has been found.
4. Repair as required.
REMOVAL
NOTE: Care must be taken to protect the intake
manifold powder coating from scrapes and abra-
sions.
1. Perform the fuel system pressure release proce-
dure,before attempting any repairs.(Refer to 14
- FUEL SYSTEM/FUEL DELIVERY - STANDARD
PROCEDURE - FUEL SYSTEM PRESSURE
RELEASE PROCEDURE).
2. Disconnect negative battery cable.
3. Disconnect throttle body air inlet duct, IAT sensor,
CCV hose and remove air cleaner cover (Refer to
9 - ENGINE/AIR INTAKE SYSTEM - REMOVAL).
4. Disconnect throttle cable (2) from throttle cam.
Remove throttle cable from bracket and set aside.
5. Disconnect speed control cable from throttle cam
and set aside.