torque DODGE RAM SRT-10 2006 Service Repair Manual

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ENGINE - 5.9L DIESEL - SERVICE
INFORMATION
DESCRIPTION
DESCRIPTION - 5.9L DIESEL .............. 2596
DESCRIPTION - CRANKCASE BREATHER . . 2597
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - MECHANICAL............... 2597
DIAGNOSIS AND TESTING - SMOKE
DIAGNOSIS CHARTS..................... 2599
DIAGNOSIS AND TESTING - CYLINDER
COMPRESSION/LEAKAGE TESTS......... 2602
STANDARD PROCEDURE
STANDARD PROCEDURE - FORM-IN-
PLACE GASKETS AND SEALERS.......... 2603
STANDARD PROCEDURE - REPAIR
DAMAGED OR WORN THREADS.......... 2604
STANDARD PROCEDURE—HYDROSTATIC
LOCK.................................... 2604
REMOVAL - ENGINE ........................ 2605
INSTALLATION - ENGINE ................... 2610
SPECIFICATIONS
SPECIFICATIONS - 5.9L DIESEL ........... 2615
TORQUE ................................. 2617
SPECIAL TOOLS
5.9L DIESEL ENGINE ..................... 2619
ENGINE DATA PLATE
DESCRIPTION ............................. 2621
AIR CLEANER ELEMENT
REMOVAL ................................. 2622
INSTALLATION ............................. 2623
CYLINDER HEAD
DESCRIPTION ............................. 2624
REMOVAL ................................. 2624
CLEANING
CLEANING ............................... 2626
CLEANING—CROSSHEADS ............... 2626
CLEANING—PUSHRODS .................. 2626
INSPECTION
INSPECTION............................. 2627
INSPECTION - CROSSHEADS . . ........... 2627
INSPECTION—PUSHRODS................ 2628
INSTALLATION ............................. 2628
COVER - CYLINDER HEAD
REMOVAL
REMOVAL - ROCKER HOUSING ........... 2632
REMOVAL - CYL HEAD COVER ............ 2632
REMOVAL - CYL HEAD COVER GASKET . . . 2634
CLEANING
CLEANING CYLINDER HEAD COVER ...... 2634
INSPECTION - CYLINDER HEAD COVER ..... 2634INSTALLATION
INSTALLATION - ROCKER HOUSING ....... 2634
INSTALLATION - CYL HEAD COVER ....... 2635
INSTALLATION - CYL HEAD COVER
GASKET................................. 2636
VALVES & SEATS - INTAKE/EXHAUST
DESCRIPTION ............................. 2638
STANDARD PROCEDURE
STANDARD PROCEDURE - VALVES,
GUIDES AND SPRINGS................... 2638
STANDARD PROCEDURE - VALVE LASH
ADJUSTMENT AND VERIFICATION......... 2643
REMOVAL ................................. 2644
INSTALLATION ............................. 2646
ROCKER ARM
DESCRIPTION ............................. 2647
REMOVAL ................................. 2647
CLEANING ................................. 2648
INSPECTION............................... 2648
INSTALLATION ............................. 2649
ENGINE BLOCK
STANDARD PROCEDURE
STANDARD PROCEDURE - CYLINDER
BLOCK REFACING........................ 2651
STANDARD PROCEDURE - CYLINDER
BORE - DE-GLAZE........................ 2651
STANDARD PROCEDURE—CYLINDER
BORE REPAIR............................ 2652
STANDARD PROCEDURE - CAM BORE
REPAIR.................................. 2655
INSPECTION............................... 2655
CAMSHAFT & BEARINGS (IN BLOCK)
REMOVAL
CAMSHAFT BEARINGS................... 2657
CAMSHAFT .............................. 2657
INSPECTION
............................... 2659
INSTALLATION
CAMSHAFT BEARINGS................... 2661
CAMSHAFT .............................. 2661
BEARINGS - CONNECTING ROD
STANDARD PROCEDURE - CONNECTING
ROD BEARING AND CRANKSHAFT
JOURNAL CLEARANCE................... 2663
CRANKSHAFT & GEAR
DESCRIPTION ............................. 2664
REMOVAL - GEAR .......................... 2664
INSTALLATION - GEAR ..................... 2664
BEARINGS - CRANKSHAFT MAIN
STANDARD PROCEDURE - MAIN BEARING
CLEARANCE ............................. 2665

DESCRIPTION - CRANKCASE BREATHER
The crankcase breather assembly is integrated into
the cylinder head cover (3) and is not serviced seper-
ately. The external fittings (2) to the breather tube and
breather drain tube are serviceable.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL
CONDITION POSSIBLE CAUSES CORRECTION
LUBRICATING OIL
PRESSURE LOW1. Low oil level. 1. (a) Check and fill with clean engine oil.
(b) Check for a severe external oil leak that
could reduce the pressure.
2. Oil viscosity thin, diluted or wrong
specification.2. (a) Verify the correct engine oil is being
used. (Refer to LUBRICATION &
MAINTENANCE/FLUID TYPES -
DESCRIPTION).
(b) Look for reduced viscosity from fuel
dilution.
3. Improperly operating pressure
switch/gauge.3. Verify the pressure switch is functioning
correctly. If not, replace switch/gauge.
4. Relief valve stuck open. 4. Check/replace valve.
6. If cooler was replaced, shipping
plugs may have been left in cooler6. Check/remove shipping plugs.
7. Worn oil pump. 7. Check and replace oil pump.
8. Suction tube loose or seal leaking. 8. Check and replace seal.
9. Loose main bearing cap. 9. Check and install new bearing. Tighten
cap to proper torque.
10. Worn bearings or wrong bearings
installed.10. Inspect and replace connecting rod or
main bearings. Check and replace directed
piston cooling nozzles.

EXCESSIVE WHITE SMOKE
POSSIBLE CAUSE CORRECTION
Fuel filter plugged. Refer to Powertrain Diagnostic Manual for fuel system
testing.
Fuel grade not correct or fuel quality is poor. Temporarily change fuel brands and note condition.
Change brand if necessary.
Fuel heater element or fuel heater temperature sensor
malfunctioning. This will cause wax type build-up in fuel
filter.Refer to Fuel Heater Testing (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY/FUEL HEATER -
DIAGNOSIS AND TESTING).
Fuel injector malfunctioning. A DTC should have been set. Perform “Cylinder
Performance Test
orCylinder cutout Testusing DRB
scan tool to isolate individual cylinders. Also refer to
Powertrain Diagnostic Procedures Information and,
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/FUEL
INJECTOR - DIAGNOSIS AND TESTING).
Fuel injector hold-downs loose. Torque to specifications.
Fuel injector protrusion not correct. Check washer (shim) at bottom of fuel injector for
correct thickness. (Referto 14 - FUEL SYSTEM/FUEL
INJECTION/FUEL INJECTOR - INSTALLATION)
Fuel injection pump malfunctioning. A DTC should have been set. Refer to Powertrain
Diagnostic Procedures Information.
Fuel supply side restriction. Refer to Powertrain Diagnostic Manual for fuel system
testing.
Fuel transfer (lift) pump malfunctioning. A DTC may have been set. Refer toPowertrain
Diagnostic Procedures Information.
Intake/Exhaust valve adjustments not correct (too tight). (Refer to 9 - ENGINE/CYLINDER HEAD/INTAKE/
EXHAUST VALVES & SEATS - STANDARD
PROCEDURE).
Intake manifold air temperature sensor malfunctioning. A DTC should havebeen set. Refer to Powertrain
Diagnostic Procedures Information.
Intake manifold heater circuit not functioning correctly in
cold weather.A DTC should have been set. Refer to Powertrain
Diagnostic Procedures Information. Also check heater
elements for correct operation.
Intake manifold heater elements not functioning
correctly in cold weather.A DTC should have been set if heater elements are
malfunctioning. Refer to Powertrain Diagnostic
Procedures Information.
Internal engine damage (scuffed cylinder). Analyze engine oil and inspect oil filter to locate area of
probable damage.
Restriction in fuel supply side of fuel system. Refer to Powertrain Diagnostic Manual for fuel system
testing.
EXCESSIVE BLUE SMOKE
POSSIBLE CAUSE CORRECTION
Dirty air cleaner or restricted turbocharger intake duct. Check Filter Minder
at air filter housing. (Refer to 9 -
ENGINE/AIR INTAKE SYSTEM/AIR CLEANER
ELEMENT - REMOVAL).
Air leak in boost system between turbocharger
compressor outlet and intake manifold.Service air charge system..
Obstruction in exhaust manifold. Remove exhaust manifold and inspect forblockage
(Refer to 9 - ENGINE/MANIFOLDS/EXHAUST
MANIFOLD - REMOVAL).

EXCESSIVE BLUE SMOKE
POSSIBLE CAUSE CORRECTION
Restricted turbocharger drain tube. Remove turbocharger drain tube and remove
obstruction.
Crankcase ventilation system plugged. Inspect crankcase ventilation system for function
Valve seals are worn, brittle, or improperly installed. Replace valve stemoilseals(Referto9-ENGINE/
CYLINDER HEAD/INTAKE/EXHAUST VALVES &
SEATS - REMOVAL).
Valve stems and/or guides are worn. Remove valves and inspect valves and guides. (Refer
to 9 - ENGINE/CYLINDER HEAD/INTAKE/EXHAUST
VALVES & SEATS - STANDARD PROCEDURE).
Broken or Improperly installed piston rings. Tear down engine and inspectpiston rings.
Excessive piston ring end gap. Remove pistons and measure piston ring end gap
(Refer to 9 - ENGINE/ENGINE BLOCK/PISTON RINGS
- STANDARD PROCEDURE).
Excessive cylinder bore wear and taper. Remove pistons and measure cylinder bore wear and
taper (Refer to 9 - ENGINE/ENGINE BLOCK -
STANDARD PROCEDURE).
Cylinder damage. Remove pistons and inspect cylinder bore for cracks or
porosity. Repair with cylinder liner if necessary. (Refer
to 9 - ENGINE/ENGINE BLOCK - STANDARD
PROCEDURE).
Piston damage. Remove pistons and inspect for cracks, holes. Measure
piston for out-of-round and taper (Refer to 9 -
ENGINE/ENGINE BLOCK/PISTON & CONNECTING
ROD - INSPECTION).
Turbocharger failure. (Refer to 11 - EXHAUST SYSTEM/TURBOCHARGER
SYSTEM/TURBOCHARGER - INSPECTION).
DIAGNOSIS AND TESTING - CYLINDER COMPRESSION/LEAKAGE TESTS
CYLINDER COMPRESSION PRESSURE
The results of a cylinder compressionpressure test can be utilized to diagnose several engine malfunctions.
Ensure batteries are completely charged and the engine starter motor is ingood operating condition. Otherwise, the
indicated compression pressures may not be valid for diagnostic purposes.
1. Disconnect the fuel inlet line to the fuel filter housing. Plug the fuel line from the fuel tank.
NOTE: Failure to plug fuel line will result in fuel leak.
2. Remove fuel transfer pump relay from PDC.
3. Start the engine and idle until the engine stalls (runs out of fuel).
4. Remove the cylinder head cover. (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) -
REMOVAL)
5. Remove the cylinder head cover carrier gasket. (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL)
6. Remove the high pressure fuel line between the cylinder head and fuel rail for the cylinder to be tested. Use
tool# 9011 to cap this fuel rail on the cylinder being tested.
7. Remove the fuel connector tube nut and fuel connector tube.
8. Remove the exhaust rocker lever.
9. Use Tool 9010 to remove the injector and copper sealing washer.
10. Install the exhaust rocker lever and torque to 36 Nꞏm (27 ft. lbs.).
11. Cover the remaining rocker levers with clean shop towels to prevent anyoil splatter under the hood.

MoparEngine 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
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. Mopar
Gasket Sealant is available in a 13 oz. aerosol can or 4oz./16 oz. can
w/applicator.
FORM-IN-PLACE GASKET AND SEALER APPLICATION
Assembling parts using a form-in-place gasket requires care but it’s easier than using precut gaskets.
Mopar
Gasket 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, a 3.17 or 6.35 mm (1/8 or 1/4 in.)
drop is placed in the center of the gasket contact area. Uncured sealant maybe removed with a shop towel. Com-
ponents should be torqued in place while the sealant is still wet to the touch (within 10 minutes). 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.
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. Disconnect the negative cable(s) from the battery.
2. Inspect air cleaner, induction system, and intake manifold to ensure system is dry and clear of foreign material.

3. Place a shop towel around the fuel injectors to catch any fluid that may possibly be under pressure in the cyl-
inder head. Remove the fuel injectors (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR -
REMOVAL).
4. With all injectors removed, rotatethe crankshaft using the crankshaftbarring tool (PN 7471–B).
5. Identify the fluid in the cylinders (coolant, fuel, oil, etc.).
6. Be sure all fluid has been removed from the cylinders.
7. Repair engine or components as necessary to prevent this problem from occurring again.
8. Squirt a small amount of engine oil into the cylinders to lubricate the walls. This will prevent damage on restart.
9. Install fuel injectors (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR - INSTALLATION).
10. Drain engine oil. Remove and discard the oil filter (Refer to 9 - ENGINE/LUBRICATION/OIL FILTER -
REMOVAL).
11. Installthedrainplug.Tightentheplugto50Nꞏm(37ft.lbs.)torque.
12. Install a new oil filter (Refer to 9 - ENGINE/LUBRICATION/OIL FILTER - INSTALLATION).
13. Fill engine crankcase with the specified amount and grade of oil (Referto LUBRICATION & MAINTENANCE/
FLUID TYPES - SPECIFICATIONS).
14. Connect the negative cable(s) to the battery.
15. Start the engine and check for any leaks.
REMOVAL - ENGINE
1. Disconnect both battery negative cables.
2. Disconnect engine grid heater harness at grid
heater relays.
3. Disconnect electrical connections from rear of alter-
nator.
4. Recover A/C refrigerant. (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - STANDARD
PROCEDURE).
5. Raise vehicle on a hoist.
6. Drain engine coolant (Refer to 7 - COOLING -
STANDARD PROCEDURE).
7. Remove engine oil drain plug and drain engine oil.
8. Reinstall drain plug. Tighten to 50 Nꞏm (37 ft. lbs.)
torque.
9. Lower the vehicle.
10. Remove fan (3) and fan drive (2). Refer to (Refer
to 7 - COOLING/ENGINE/RADIATOR FAN -
REMOVAL).

NOTE: Extreme care should be used to keep dirt/debris from entering the fuel lines. Plastic caps should be
used on the ends of the fuel lines.
46. Loosen # 6 fuel line shield bolts and rotate shield out of the way.
47. Remove cylinder # 5 and # 6 high pressure fuel lines.
48. Remove the rear engine lift bracket.
49. Remove cylinder # 4, # 5, and # 6 intake and
exhaust rocker arms (1), pedestals (2), and push
tubes. Note the original location for reassembly.
50. Remove the fuel connector tube nut and fuel con-
nector tube. Remove cylinder # 5 and # 6 fuel
injector.
51. Remove rocker housing.
52. Remove two cylinder head bolts (1) according to
the diagram and install Tool # 9009 (2). Torque
bolts to 105 Nꞏm (77 ft. lbs.).
53. Loosen but do not remove engine mount through
bolts and nuts.
54. Disconnect hood support struts and position hood
out of the way.
55. Attach a chain with two hooks to the engine lift
brackets.
56. While keeping engine level, lift straight up out of
the mounts.
57. Rotate nose of engine upward and pull out of
chassis.

INSTALLATION - ENGINE
1. Remove cylinder head bolts (1,3) according to the
diagram. Install special Tool 9009 (2). Torque bolts
to 105 Nꞏm (77 ft. lbs.)
2. Lower engine into the engine compartment and
install the engine mount through bolts and nuts.
3. Tighten the mount through bolts and nuts to 88
Nꞏm (65 ft. lbs) torque.
4. Remove the engine lifting device (Tool 9009).
5. Check cylinder head capscrew length and install
into cylinder head.
6. Torque in 4 steps to:
Step 1—Tighten to 70 Nꞏm (52 ft. lbs.) torque.
Step 2—Back off 360°.
Step 3—Tighten to 105 Nꞏm (77 ft. lbs.) torque.
Step 4—Rotate 90°.
7. Install rocker housing. Torque to 24 Nꞏm (18 ft. lbs). Refer to (Refer to 9- ENGINE/CYLINDER HEAD/CYLINDER
HEAD COVER(S) - INSTALLATION).
8. Replace injector o-ring and sealing washer on injectors # 5 and # 6. Install injectors and torque using the fol-
lowing steps:
Step 1—Install injector hold-down capscrews and torque to 5 Nꞏm (44 in. lbs.) torque.
Step 2—Loosen injector hold-down capscrews.
Step 3—Install HPC connector tube and nut. Torque nut to 15 Nꞏm (11 ft. lbs.)torque.
Step 4—Torque injector hold-down capscrews to 10 Nꞏm (89 in. lbs.) torque.
Step 5—Torque HPC connector tube nut to 50 Nꞏm (37 ft. lbs.) torque.
9. Install rear engine lift bracket. Torque to 77 Nꞏm (57 ft. lb).
10. Install # 5 and # 6 high pressure fuel lines. Follow correct torque sequence per section 14. Torque fuel line
fittings to 30 Nꞏm (22 ft. lb). Torque brace capscrew and nut to 24 Nꞏm (18 ft.lb).
11. Install push tubes, rocker arms (1), and pedestals
(2) for cylinders # 4, # 5, and # 6. Torque the
mounting bolts to 36 Nꞏm (27 ft. lbs).
12. Reset valve lash on cylinders # 4, # 5, and # 6.
Torque adjusting nuts to 24 Nꞏm (18 ft. lbs).
13. Install injector wiring/gasket.

14. Install cylinder head cover carrier gasket (2).
15. Connect injector harness nuts to injectors (1). Torque to 1.25 Nꞏm (11 in. lbs. )
16. Connect injector wiring harness connectors to injector connections on cylinder head cover carrier gasket (3).

19. Connect fuel supply and return hoses.
20. Connect ECM ground to hydroform screw. Con-
nect ECM power connector.
21. Install the power steering pump.
22. Install the damper and speed indicator ring.
Torque to 40 Nꞏm (30 ft. lb) plus 60 degrees.
23. Install lower fan shroud bracket (3). Torque to 24
Nꞏm (18 ft. lb).
24. Install upper fan shroud brackets, but do not
tighten fasteners at this time.
25. Connect the engine block heater connection.
26. Connect the A/C compressor and pressure sensor
connectors
27. Install the charge air cooler (2). Install and tighten
the charge air cooler mounting bolts (1) to 2 Nꞏm
(17 in. lbs).
28. Connect the charge air cooler tubes (4). Torque all
clampsto8Nꞏm(72in.lbs).