DODGE RAM SRT-10 2006 Service Repair Manual

6. Use a drill, a fine grit Flex-hone and a mixture of
equal parts of mineral spirits and SAE 30W engine
oil to de-glaze the bores.
7. The crosshatch angle is a function of drill speed
and how fast the hone is moved vertically.
8. Vertical strokes MUST be smooth continuous
passes along the full length of the bore.
9. Inspect the bore after 10 strokes.
10. Use a strong solution of hot water and laundry
detergent to clean the bores. Clean the cylinder
bores immediately after de-glazing.
11. Rinse the bores until the detergent is removed
and blow the block dry with compressed air.
12. Check the bore cleanliness by wiping with a
white, lint free, lightly oiled cloth. If grit residue is still present, repeat the cleaning process until all residue is
removed. Wash the bores and the complete block assembly with solvent and dry with compressed air. Place a
clean shop towel around the top main bearing saddle to deflect water and residue from piston cooling nozzels.
Remove directed piston cooling nozzles if installed.
13. Be sure to remove the tape covering the lube holes, rod journals, and piston cooling nozzles after the cleaning
process is complete.
STANDARD PROCEDURE—CYLINDER BORE REPAIR
Cylinder bore(s) can be repaired by one of two methods:
Method 1:—Over boring and using oversize pistons and rings.
Method 2:—Boring and installing a repair sleeve to return the bore to standard dimensions.
METHOD 1—OVERSIZE BORE
Cylinder bore(s) can be repaired by one of two methods:
Oversize pistons and rings are available in two sizes - 0.50 mm (0.0197 inch) and 1.00 mm (0.0393 inch).
Any combination of standard, 0.50 mm (0.0197 inch) or 1.00 mm (0.0393 inch)overbore may be used in the same
engine.
If more than 1.00 mm (0.0393 inch) overbore is needed, a repair sleeve can beinstalled (refer to Method 2—Repair
Sleeve).
Cylinder block bores may be bored twice before use of a repair sleeve is required. The first bore is 0.50 mm
(0.0197 inch) oversize. The second bore is 1.00 mm (0.0393 inch) oversize.
After boring to size, use a honing stone to chamfer the edge of the bore.
CYLINDER BORE DIMENSION CHART
DESCRIPTION MEASUREMENT
BORING DIAMETER DIMENSION 1st. REBORE - 102.469 mm (4.0342 in.)
2nd. REBORE - 102.969 mm (4.0539 in.)
HONING DIAMETER DIMENSIONS STANDARD - 102.020 ± 0.020 mm (4.0165 ± 0.0008
in.)
1st. REBORE - 102.520 ± 0.020 mm (4.0362 ± 0.0008
in.)
2nd. REBORE - 103.020 ± 0.020 mm 4.0559 ± 0.0008
in.)
CHAMFER DIMENSIONS Approx. 1.25 mm (0.049 in.) by 30°

A correctly honed surface will have a crosshatch
appearance with the lines at 15° to 25° angles with
the top of the cylinder block. For the rough hone, use
80 grit honing stones. To finish hone, use 280 grit hon-
ing stones.
A maximum of 1.2 micrometer (48 microinch) surface
finish must be obtained.
After finish honing is complete, immediately clean the
cylinder bores with a strong solution of laundry deter-
gent and hot water.
After rinsing, blow the block dry.
Check the bore cleanliness by wiping with a white, lint-free, lightly- oiled cloth. There should be no grit residue
present.
If the block is not to be used right away, coat it with a rust- preventing compound.
METHOD 2—REPAIR SLEEVE
REPAIR SLEEVE BLOCK REBORE DIMENSIONS
CHART
BORE DIAMETER STEP DIMENSION
104.500 + 0.015 mm (4.1142 + 0.0006 in.) 6.35 mm (0.25 in.)
If more than a 1.00 mm (0.03937 inch) diameter oversize bore is required, the block must be bored and a repair
sleeve installed.
Bore the block cylinder bore to 104.500-104.515 mm (4.1142-4.1148 inch).
Repair sleeves can be replaced by using a boring bar to bore out the old sleeve. DO NOT cut the cylinder bore
beyond the oversize limit.
After machining the block for the new repair sleeve,
thoroughly clean the bore of all metal chips, debris
and oil residue before installing the sleeve.
Cool the repair sleeve(s) to a temperature of -12°C
(10°F) or below for a minimum of one hour. Be ready
to install the sleeve immediately after removing it from
the freezer.
Apply a coat of Loctite 620, or equivalent to the bore
that is to be sleeved.
Wear protective gloves to push the cold sleeve into
the bore as far as possible.

Using a sleeve driver (1), drive the sleeve (2) downward until it contacts the step at the bottom of the bore.
SLEEVE DRIVER CONSTRUCTION SPECIFICATION
CHART
ITEM MEASUREMENT
A127mm(5in.)
B 38mm(1.5in.)
C 6.35 mm (0.25 in.)
D 25.4 mm (1 in.)
E 101 mm (3.976 in.)
F 107.343 mm (4.226 in.)
A sleeve driver can be constructed as shown.
SLEEVE MACHINING DIMENSIONS CHART
ITEM MEASUREMENT
SLEEVE PROTRUSION MIN. - FLUSH WITH BLOCK
MAX. - 0.050 mm (0.0019 in.)
SLEEVE DIAMETER 101.956 mm (4.014 in.)
SLEEVE CHAMFER APPROX. 1.25 mm (0.049 in.) by 15°
Set up a boring bar and machine the sleeve to 101.956 mm (4.014 inch).
After removing the boring bar, use a honing stone to chamfer the corner of the repair sleeve(s).
A correctly honed surface will have a crosshatch appearance with the linesat 15° to 25° angles with the top of the
cylinder block. For the rough hone, use 80 grit honing stones. To finish hone, use 280 grit honing stones.
Finished bore inside dimension is 102.020 ±0.020 mm (4.0165 ±0.0008 inch).
A maximum of 1.2 micrometer (48 microinch) surface finish must be obtained.
After finish honing is complete, immediately clean the cylinder bores with a strong solution of laundry detergent and
hot water.
After rinsing, blow the block dry with compressed air.
Wipe the bore with a white, lint-free, lightly oiled cloth. Make sure thereis no grit residue present.
Apply a rust-preventing compound if the block will not be used immediately.
A standard diameter piston and a piston ring set must be used with a sleeved cylinder bore.

STANDARD PROCEDURE - CAM BORE REPAIR
For standard bushings, not oversized, maximum front
cam bushing bore diameter is 59.248 mm. (2.3326
in.). DO NOT bore the intermediate cam bore to the
front cam bore oversize dimensions. Maximum front
camshaft bushing installed diameter is 54.147 mm.
(2.1318 in.). Minimum installed diameter is 54.083
mm. (2.1293 in.). Maximum intermediate camshaft
bore diameter is 54.164 mm. (2.1324 in.).
A surface finish of 2.3 micrometers (92 microinch)
must be maintained. Not more than 20% of an area of
any one bore may be 3.2 micrometers (126 micro-
inch).
Camshaft bores can be repaired individually. It is not necessary to repairundamaged cam bores in order to repair
individually damaged cam bores. The standard front bushing (1) cannot be used to repair intermediate bores.
Install all cam bushings flush or below the front and rear cam bore surface.The front camshaft bushing should be
installed flush with front face of block. The oil hole must align to allow a 3.2 mm (0.125 inch) rod to pass through
freely.
INSPECTION
Measure the combustion deck face using a straight
edge (1) and a feeler gauge (2). Cylinder block flat-
ness: End-to-end 0.076 mm ( .003 in.). Maximum vari-
ation side-to-side 0.051 mm (.002 in.).
Inspect for any localized dips or imperfections.
If the surface exceeds the limit, (Refer to 9 - ENGINE/
ENGINE BLOCK - STANDARD PROCEDURE).
BORE SPECIFICATIONS
BORE DIAMETER
Min. 102.000 mm (4.0157 in.)
Max. 102.116 mm (4.0203 in.)
OUT OF ROUNDNESS
Max. 0.038 mm (0.0015 in.)
TA P E R
Max. 0.076 mm (.003 in.)

Inspect the cylinder bores for damage or excessive wear.
Measure the cylinder bores. If the cylinder bores exceed the limit, (Referto 9 - ENGINE/ENGINE BLOCK - STAN-
DARD PROCEDURE).
Inspect the camshaft bores for scoring or excessive wear.
Measure the camshaft bores (Refer to 9 - ENGINE - SPECIFICATIONS).
If a bore exceeds the limit, (Refer to 9 - ENGINE/ENGINE BLOCK/CAMSHAFT & BEARINGS (IN BLOCK) - STAN-
DARD PROCEDURE).
Inspect the tappet bores for scoring or excessive wear.
Measure tappet bore from bottom of block. Minimum tappet bore diameter 16.000 mm (0.0630 in.). Maximum tappet
bore 16.055 mm. (0.632 in.).
If out of limits, replace the cylinder block.

CAMSHAFT & BEARINGS (IN BLOCK)
REMOVAL
CAMSHAFT BEARINGS
NOTE: Measure the diameter of each bore. If the camshaft bore for the cam bushing is worn beyond the
limit, install a new service bushing. Inspect the rest of the camshaft bores for damage or excessive wear.If
the bores without a bushing are worn beyond the limit, the engine must be removed for machining and
installation of service bushings. If badly worn, replace the cylinder block.
1. Remove the camshaft (Refer to 9 - ENGINE/ENGINE BLOCK/CAMSHAFT & BEARINGS (IN BLOCK) -
REMOVAL).
2. Remove the bushing from the No.1 bore.
3. Mark the cylinder block so you can align the oil hole in the cylinder blockwith the oil hole in the bushing.
CAMSHAFT
1. Disconnect both battery negative cables.
2. Recover A/C refrigerant (if A/C equipped) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STAN-
DARD PROCEDURE).
3. Raise vehicle on hoist.
4. Drain engine coolant into container suitable for re-use (Refer to 7 - COOLING - STANDARD PROCEDURE).
5. Lower vehicle.
6. Remove radiator upper hose.
7. Remove viscous fan/drive/shroud assembly (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - REMOVAL).
8. Disconnect the coolant recovery bottle hose from the radiator filler neck.
9. Disconnect lower radiator hose from radiator outlet.
10.Automatic Transmission models:Disconnect transmission oil cooler lines from front of radiator using Special
Tool 6931 (unless equipped with finger-release disconnect).
11. Remove radiator mounting screws and lift radiator out of engine compartment.
12. Remove upper radiator support panel.
13. If A/C equipped, disconnect A/C condenser refrigerant lines.
14. Disconnect charge air cooler piping from the cooler inlet and outlet.
15. Remove the two charge air cooler mounting bolts.
16. Remove charge air cooler (and A/C condenser if equipped) from vehicle.
17. Remove accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
18. Remove accessory drive belt tensioner.
19. Remove the fan support/hub assembly.
20. Remove crankshaft damper and speed indicator ring (Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL).
21. Remove the gear cover-to-housing bolts and gently pry the cover away from the housing, taking care not to mar
the sealing surfaces. Remove dust seal with cover.
22. Using Special Tool 7471–B Crankshaft Barring Tool, rotate the crankshaft to align the timing marks on the
crankshaft and the camshaft gears.
23. Remove the cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) -
REMOVAL).

24. Remove the rocker arms, cross heads, and push
rods. Mark each component so they can be
installed in their original positions.
NOTE: The # 5 cylinder intake and the # 6 cylinder
intake and exhaust pushrods are removed by lift-
ing them up and through the provided cowl panel
access holes. Remove the rubber plugs to expose
these relief holes.
25. Raise the tappets as follows, using the wooden
dowel rods provided withthe Miller Tool Kit 8502.
a. Insert the slotted end of the dowel rod into the
tappet.The dowel rods for the rear two cyl-
inders will have to be cut for cowl panel
clearance.Press firmly to ensure that it is
seated in the tappet.
b. Raise the dowel rod to bring the tappet to the
top of its travel, and wrap a rubber band
around the dowel rods to prevent the tappets
from dropping into the crankcase.
c. Repeat this procedure for the remaining
cylinders.
26. Verify that the camshaft timing marks are aligned
with the crankshaft mark.
27. Remove the bolts from the thrust plate.
28. Remove engine mount through bolts.
29. Install engine support fixture special tool # 8534,
and steel bracket/wing nut special tool #
8534A.
30. Raise engine enough to allow camshaft removal.
31. Remove the camshaft, gear and thrust plate.

INSPECTION
Camshaft
CAMSHAFT DIMENSIONS
CAMSHAFT DIMENSIONS
Journal diameter (No.1 and No.7)
Min. 54.028 mm. (2.127 in.)
Max. 54.048 mm. (2.128 in.)
Journal diameter (No.2 through No.6)
Min.53.962 mm. (2.1245 in.)
Max.54.013 mm. (2.1265 in.)
Diameter of peak of lobe
Intake
Min.47.175 mm (1.857 in.)
Max47.855 mm.
Exhaust
Min. 45.632 mm. (1.797 in.)
Max. 46.312 mm. (1.823 in.)
1. Inspect the valve lobes (1) and bearing journals (2)
for cracks, pitting, scoring, or generally excessive
wear. Replace any camshaft that exceeds the
allowable limits.
2. Measure the bearing journals and lobes.
CAUTION: If Camshaft lobes are worn, requiring
camshaft replacement, it is necessary to replace
the tappets also. (Refer to 9 - ENGINE/ENGINE
BLOCK/SOLID LIFTERS - REMOVAL).

Camshaft Bushing/Bores
Camshaft bores No. 2–7do notuse a bushing.
1. Inspect the camshaft bushing and bores for signs
of excessive wear.
2. Measure the camshaft bushing and bores with a
telescoping bore gauge and micrometer. If out of
specification, (Refer to 9 - ENGINE/ENGINE
BLOCK/CAMSHAFT & BEARINGS (IN BLOCK) -
REMOVAL).
3. Inspect the camshaft bushing (1) oil holes for align-
ment with cylinder block.
Camshaft Gear
Inspect the camshaft gear for cracks (gear and hub), and chipped/broken/fretted teeth. If replacement is necessary,
camshaft and gear are replaced as an assembly. (Refer to 9 - ENGINE/ENGINE BLOCK/CAMSHAFT & BEARINGS
(IN BLOCK) - REMOVAL).
Thrust Plate
CAMSHAFT THRUST PLATE THICKNESS CHART
MIN. 9.34 mm (0.368 in.)
MAX. 9.60 mm (0.378 in.)
Inspect the camshaft thrust plate for excessive wear in the camshaft contact area. Measure thrust plate thickness
using the CAMSHAFT THRUST PLATE THICKNESS CHART . Replace any thrust platethat falls outside of these
specifications:

INSTALLATION
CAMSHAFT BEARINGS
1. Apply a coating of Loctite640 Adhesive to the
backside of the new bushing. Avoid getting adhe-
sive in the oil hole.
2. Use a universal cam bushing installation tool and
install the front bushing (1) so that it is even with
the front face of the cylinder block. The oil hole
must be aligned. A 3.2 mm (0.128 inch) diameter
rod must be able to pass through the hole.
3. Measure the installed bushings at the front bore.
The minimum inside diameter is 54.083 mm
(2.1293 inch), and the maximum inside diameter is
is 54.147 mm. (2.1318 in.).
CAMSHAFT
1. Lubricate the camshaft bushing and bores with
fresh engine oil or suitable equivalent.
2. Liberally coat the camshaft lobes, journals, and
thrust washer with fresh engine oil or suitable
equivalent.
CAUTION: When installing the camshaft, DO NOT
push it in farther than it will go with the thrust
washer in place.
3. Install the camshaft and thrust plate. Align the tim-
ing marks as shown.
BACKLASH - 0.075 - 0.250 mm (0.003 - 0.010 inch)
CLEARANCE - 0.025 - 0.500 mm (0.001 - 0.020 inch)
4. Install the thrust plate bolts and tighten to 24 Nꞏm (18 ft. lbs.) torque.
5. Measure camshaft back lash and end clearance.
6. Remove the wooden dowel rods and rubber bands from the tappets.
7. Lubricate the push rods with engine oil and install in their original location.Verify that they are seated in the
tappets.
8. Lubricate the valve tips with engine oil and install the crossheads in their original locations.
9. Lubricate the crossheads and push rod sockets with engine oil and install the rocker arms and pedestals in their
original locations. Tighten bolts to 36 Nꞏm (27 ft. lbs.) torque.
10.Verify valve lash adjustment (Refer to 9 - ENGINE/CYLINDER HEAD/INTAKE/EXHAUST VALVES & SEATS
- STANDARD PROCEDURE).
11. Install the cylinder head cover. (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) -
INSTALLATION)