DODGE RAM SRT-10 2006 Service Repair Manual

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.

18. Using Special Tool 6958, Spanner with Adaptor
Pins 8346, tighten left (3) and right (4), camshaft
sprocket bolts to 122 Nꞏm (90 ft. lbs.).
19. Rotate engine two full revolutions. Verify timing
marks are at the follow locations:
primary chain idler sprocket dot is at 12 o’clock
primary chain crankshaft sprocket dot is at 6
o’clock
secondary chain camshaft sprockets “V8” marks
are at 12 o’clock
20. Lubricate all three chains with engine oil.
21. After installing all chains, it is recommended that
the idler gear (1) end play be checked. The end
play must be within 0.10–0.25 mm (0.004–0.010
in.). If not within specification, the idler gear must
be replaced.
22. Install timing chain cover (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT / CHAIN COV-
ER(S) - INSTALLATION) and crankshaft damper
(Refer to 9 - ENGINE/ENGINE BLOCK/VIBRA-
TION DAMPER - INSTALLATION).
23. Install cylinder head covers (Refer to 9 - ENGINE/
CYLINDER HEAD/CYLINDER HEAD COVER(S) -
INSTALLATION).
NOTE: Before installing threaded plug in right cyl-
inder head, the plug mustbecoatedwithsealant
to prevent leaks.
24. Coat the large threaded access plug withMopar
Thread Sealant with Teflon, then install into the
right cylinder head and tighten to 81 Nꞏm (60 ft.
lbs.).
25. Install the oil fill housing.
26. Install access plug in left cylinder head.

27. Install power steering pump (Referto19-STEERING/PUMP-INSTALLATION).
28. Install radiator fan shroud.
29. Fill cooling system (Refer to 7 - COOLING - STANDARD PROCEDURE).
30. Connect negative cable to battery.

SHAFT - IDLER
REMOVAL
1. Remove the primary and secondary timing chains and sprockets (Refer to 9- ENGINE/VALVE TIMING/TIMING
BELT/CHAIN AND SPROCKETS - REMOVAL) .
NOTE: To remove the idler shaft, it is necessary to tap threads into the shaft, to install the removal tool.
2. Using a 12 mm X 1.75 tap, cut threads in the idler shaft center bore.
3. Cover the radiator core with a suitable cover.
CAUTION: Use care when removing the idler shaft, Do not strike the radiatorcooling fins with the slide
hammer.
4. Using Special Tool 8517 Slide Hammer, remove the idler shaft.
INSTALLATION
1. Thoroughly clean the idler shaft bore.
2. Position the idler shaft in the bore.
NOTE: The two lubrication holes in the idler shaft do not require any specialalignment.
NOTE: Before using the retaining bolt to install the idler shaft, coat the threads and the pilot on the idler
shaft, with clean engine oil.
3. Using the primary idler sprocket retaining bolt and washer, carefully draw the idler shaft into the bore until fully
seated.
4. Coat the idler shaft with clean engine oil.
5. Install the timing chains and sprockets (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION) .

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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

INSPECTION ............................... 2548
INSTALLATION ............................. 2549
RINGS - PISTON
STANDARD PROCEDURE - PISTON RING
FITTING .................................. 2551
DAMPER - CRANKSHAFT
REMOVAL ................................. 2554
INSTALLATION ............................. 2554
COVER - STRUCTURAL
DESCRIPTION ............................. 2556
OPERATION ............................... 2556
REMOVAL ................................. 2556
INSTALLATION ............................. 2557
SOLENOID-MDS
DESCRIPTION ............................. 2559
OPERATION ............................... 2559
DIAGNOSIS AND TESTING .................. 2559
REMOVAL ................................. 2560
INSTALLATION ............................. 2560
MOUNT - FRONT
REMOVAL ................................. 2561
INSTALLATION ............................. 2563
MOUNT - REAR
REMOVAL ................................. 2565
INSTALLATION ............................. 2565
LUBRICATION
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - CHECKING
ENGINE OIL PRESSURE.................. 2566
DIAGNOSIS AND TESTING - ENGINE OIL
LEAK.................................... 2566
OIL
STANDARD PROCEDURE - ENGINE OIL
SERVICE ................................. 2568
FILTER - ENGINE OIL
REMOVAL ................................. 2569INSTALLATION ............................. 2569
PA N - E N G I N E O I L
REMOVAL ................................. 2570
INSTALLATION ............................. 2571
PUMP - ENGINE OIL
DESCRIPTION ............................. 2574
REMOVAL ................................. 2575
CLEANING ................................. 2575
INSPECTION............................... 2576
INSTALLATION ............................. 2577
MANIFOLD - INTAKE
DESCRIPTION ............................. 2578
DIAGNOSIS AND TESTING - INTAKE
MANIFOLD LEAKAGE ..................... 2578
REMOVAL ................................. 2578
CLEANING ................................. 2578
INSPECTION............................... 2579
INSTALLATION ............................. 2579
MANIFOLD - EXHAUST
DESCRIPTION ............................. 2580
OPERATION ............................... 2580
REMOVAL ................................. 2580
CLEANING ................................. 2581
INSPECTION............................... 2581
INSTALLATION ............................. 2581
COVER - TIMING
REMOVAL ................................. 2583
INSTALLATION ............................. 2585
TIMING CHAIN & SPROCKETS
REMOVAL ................................. 2587
INSTALLATION ............................. 2590
TENSIONER - TIMING CHAIN
DESCRIPTION ............................. 2593
OPERATION ............................... 2593

ENGINE - 5.7L - SERVICE INFORMATION
DESCRIPTION
The 5.7L engine (345 CID) eight-cylinder engine is a 90° V-Type lightweight, deep skirt cast iron block, aluminum
heads, single cam, overhead valve engine with hydraulic roller tappets. The heads incorporate splayed valves with
a hemispherical style combustion chamber and dual spark plugs. The cylinders are numbered from front to rear; 1,
3, 5, 7 on the left bank and 2, 4, 6, 8 on the right bank. The firing order is 1-8-4-3-6-5-7-2.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - INTRODUCTION
Engine diagnosis is helpful in determining the causes of malfunctions notdetected and remedied by routine main-
tenance.
These malfunctions may be classified as either performance (e.g., engineidles rough and stalls) or mechanical
(e.g., a strange noise).
(Refer to 9 - ENGINE - DIAGNOSIS AND TESTING) - PERFORMANCE and (Refer to 9 - ENGINE - DIAGNOSIS
AND TESTING)—MECHANICAL for possible causes and corrections of malfunctions. (Refer to 14 - FUEL SYSTEM/
FUEL DELIVERY - DIAGNOSIS AND TESTING) and (Refer to 14 - FUEL SYSTEM/FUEL INJECTION - DIAGNO-
SIS AND TESTING) for the fuel system diagnosis.
Additional tests and diagnostic procedures may be necessary for specificengine malfunctions that can not be iso-
lated with the Service Diagnosis charts. Information concerning additional tests and diagnosis is provided within the
following diagnosis:
Cylinder Compression Pressure Test (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING).
Cylinder Combustion Pressure LeakageTest (Refer to 9 - ENGINE - DIAGNOSISAND TESTING).
Engine Cylinder Head Gasket Failure Diagnosis (Refer to 9 - ENGINE/CYLINDER HEAD - DIAGNOSIS AND
TESTING).
Intake Manifold Leakage Diagnosis (Refer to 9 - ENGINE/MANIFOLDS/INTAKEMANIFOLD - DIAGNOSIS
AND TESTING).
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE
CONDITION POSSIBLE CAUSE CORRECTION
ENGINE WILL NOT START 1. Weak battery 1. Charge or replace as necessary.
2. Corroded or loose battery
connections.2. Clean and tighten battery
connections. Apply a coat of light
mineral grease to the terminals.
3. Faulty starter. 3. (Refer to 8 - ELECTRICAL/
STARTING - DIAGNOSIS AND
TESTING).
4. Faulty coil or control unit. 4. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/IGNITION
COIL - REMOVAL).
5. Incorrect spark plug gap. 5. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/SPARK PLUG
- CLEANING).
6. Dirt or water in fuel system. 6. Clean system and replace fuel
filter.
7. Faulty fuel pump, relay or wiring. 7. Repair or replace as necessary.

CONDITION POSSIBLE CAUSE CORRECTION
ENGINE STALLS OR ROUGH IDLE 1. Idle speed set to low. 1. (Refer to 14 - FUEL SYSTEM/
FUEL INJECTION/IDLE AIR
CONTROL MOTOR - REMOVAL).
2. Idle mixture too lean or too rich. 2. Refer to Powertrain Diagnosis
Information.
3. Vacuum leak. 3. Inspect intake manifold and
vacuum hoses, repair or replace as
necessary.
4. Faulty coil. 4. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/IGNITION
COIL - REMOVAL).
5. Incorrect engine timing. 5. (Refer to 9 - ENGINE/VALVE
TIMING - STANDARD
PROCEDURE).
ENGINE LOSS OF POWER 1. Dirty or incorrectly gapped spark
plugs.1. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/SPARK PLUG
- CLEANING).
2. Dirt or water in fuel system. 2. Clean system and replace fuel
filter.
3. Faulty fuel pump. 3. Refer to the Appropriate
Diagnostic Information
4. Blown cylinder head gasket. 4. Replace cylinder head gasket.
5. Low compression. 5. (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING).
6. Burned, warped or pitted valves. 6. Replace as necessary.
7. Plugged or restricted exhaust
system.7. Inspect and replace as
necessary.
8. Faulty coil. 8. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/IGNITION
COIL - REMOVAL).
ENGINE MISSES ON
ACCELERATION1. Spark plugs dirty or incorrectly
gapped.1. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/SPARK PLUG
- CLEANING).
2. Dirt in fuel system. 2. Clean fuel system.
3. Burned, warped or pitted valves. 3. Replcae as necessary.
4. Faulty coil. 4. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/IGNITION
COIL - REMOVAL).
ENGINE MISSES AT HIGH SPEED 1. Spark plugs dirty or incorrectly
gapped.1. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/SPARK PLUG
- CLEANING).
2. Faulty coil. 2. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/IGNITION
COIL - REMOVAL).
3. Dirt or water in fuel system. 3. Clean system and replace fuel
filter.

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.