heating DODGE RAM SRT-10 2006 Service User Guide

INSTALLATION
CAUTION: Do not use oil based liquids to clean
timing cover or block surfaces. Use only rubbing
alcohol, along with plastic or wooden scrapers.
Use no wire brushes or abrasive wheels or metal
scrapers, or damage to surfaces could result.
1. Clean timing chain cover and block surface using
rubbing alcohol.
CAUTION: The 3.7L uses a special anerobic sealer
instead of a gasket to seal the timing cover to the
engine block, from the factory. For service repairs,
Mopar
Engine Grey RTV must be used as a sub-
stitute.
2. Inspect the water passage o-rings for any damage,
and replace as necessary.
3. Apply Mopar
Grey Engine RTV sealer (3) to front
cover(1)followingthepathprovidedusinga3to
4mm thick bead (3).
4. Install cover. Tighten fasteners in sequence as
showninto58Nꞏm(43ft.lbs.).
5. Install crankshaft damper (Refer to 9 - ENGINE/
ENGINE BLOCK/VIBRATION DAMPER - INSTAL-
LATION).
6. Install the A/C compressor (Refer to 24 - HEATING
& AIR CONDITIONING/PLUMBING/A/C COM-
PRESSOR - INSTALLATION).
7. Install the generator (Refer to 8 - ELECTRICAL/
CHARGING/GENERATOR - INSTALLATION).
8. Install accessory drive belt tensioner assembly
(Refer to 7 - COOLING/ACCESSORY DRIVE/BELT
TENSIONERS - INSTALLATION).
9. Install radiator upper and lower hoses.
10. Install both heater hoses.
11. Install electric fan shroud and viscous fan drive
assembly (Refer to 7 - COOLING/ENGINE/FAN
DRIVE VISCOUS CLUTCH - INSTALLATION).
12. Fill cooling system (Refer to 7 - COOLING - STANDARD PROCEDURE).
13. Connect the battery negative cable.

13. Drain cooling system (Refer to 7 - COOLING - STANDARD PROCEDURE).
14. Remove torque converter bolts (Automatic Transmission Only).
15. Remove transmission to engine mounting bolts.
16. Disconnect the engine block heater power cable from the block heater, if equipped.
17. Lower vehicle.
18. Remove throttle body resonator assembly and air inlet hose.
19. Disconnect throttle and speed control cables.
20. Disconnect tube from both the left and right side
crankcase breathers (1). Remove breathers
21. Discharge A/C system (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING/REFRIGERANT
- STANDARD PROCEDURE).
22. Remove A/C compressor (2) (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING/A/C
COMPRESSOR - REMOVAL).
23. Remove shroud, fan assembly (Refer to 7 -
COOLING/ENGINE/FAN DRIVE VISCOUS
CLUTCH - REMOVAL) and accessory drive belt
(Refer to 7 - COOLING/ACCESSORY DRIVE/
DRIVE BELTS - REMOVAL).
24. Disconnect transmission oil cooler lines at the
radiator.
25. Disconnect radiator upper and lower hoses.
26. Remove radiator (Refer to 7 - COOLING/ENGINE/
RADIATOR - REMOVAL), A/C condenser (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING/A/C CONDENSER - REMOVAL) and trans-
mission oil cooler.

12. Position and install heater hoses (1) and tubes
onto intake manifold.
13. Install the heater hoses onto the heater core and
the engine front cover, and install clips (2).
14. Install generator (3) (Refer to 8 - ELECTRICAL/
CHARGING/GENERATOR - INSTALLATION).
15. Install A/C condenser (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/A/C CONDENSER - INSTAL-
LATION), radiator (Refer to 7 - COOLING/ENGINE/RADIATOR - INSTALLATION)and transmission oil cooler.
16. Connect radiator upper and lower hoses.
17. Connect the transmission oil cooler lines to the radiator.
18. Install accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION), fan
assembly and shroud (Refer to 7 - COOLING/ENGINE/FAN DRIVE VISCOUS CLUTCH- INSTALLATION).

28. Install starter (4) (Refer to 8 - ELECTRICAL/
STARTING/STARTER MOTOR - INSTALLATION).
CAUTION: The structural cover requires a specific
torque sequence. Failure to follow this sequence
may cause severe damage to the cover.
29. Install structural cover (Refer to 9 - ENGINE/EN-
GINE BLOCK/STRUCTURAL COVER - INSTAL-
LATION) .
30. Install exhaust crossover pipe.
31. Install engine block heater power cable, If
equipped.
32.4X4 vehiclesConnect axle vent tube to left side
engine mount.
33. Lower vehicle.
34. Check and fill engine oil.
35. Recharge the A/C system (Refer to 24 - HEATING
& AIR CONDITIONING/PLUMBING/REFRIGERANT - STANDARD PROCEDURE).
36. Refill the engine cooling system (Refer to 7 - COOLING - STANDARD PROCEDURE).
37. Connect the battery positive and negative cables.
38. Start the engine and check for leaks.
SPECIFICATIONS
SPECIFICATIONS - 4.7L ENGINE
GENERAL DESCRIPTION
DESCRIPTION SPECIFICATION
Engine Type 90° SOHC V-8 16-Valve
Displacement 4.7 Liters / 4701 cc
287 ( Cubic Inches)
Bore 93.0 mm (3.66 in.)
Stroke 86.5 mm (3.40 in.)
Compression Ratio 9.0:1
Horsepower 235 BHP @ 4800 RPM
Torque 295 LB-FT @ 3200 RPM
Lead Cylinder #1 Left Bank

CYLINDER HEAD
DESCRIPTION
DESCRIPTION - CYLINDER HEAD
The cylinder heads are made of an aluminum alloy. The cylinder head features two valves per cylinder with pressed
in powdered metal valve guides. The cylinder heads also provide enclosures for the timing chain drain, necessitating
unique left and right cylinder heads.
DESCRIPTION - VALVE GUIDES
The valve guides are made of powered metal and are pressed into the cylinderhead. The guides are not replace-
able or serviceable, and valve guide reaming is not recommended. If the guides are worn beyond acceptable limits,
replace the cylinder heads.
DIAGNOSIS AND TESTING
CYLINDER HEAD GASKET
A cylinder head gasket leak can be located between adjacent cylinders or between a cylinder and the adjacent
water jacket.
Possible indications of the cylinder head gasket leaking between adjacent cylinders are:
Loss of engine power
Engine misfiring
Poor fuel economy
Possible indications of the cylinder head gasket leaking between a cylinder and an adjacent water jacket are:
Engine overheating
Loss of coolant
Excessive steam (white smoke) emitting from exhaust
Coolant foaming
CYLINDER-TO-CYLINDER LEAKAGE TEST
To determine if an engine cylinder head gasket is leaking between adjacentcylinders, follow the procedures in Cyl-
inder Compression Pressure Test (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING). An engine cylinder head
gasket leaking between adjacent cylinders will result in approximately a50 - 70% reduction in compression pres-
sure.
CYLINDER-TO-WATER JACKET LEAKAGE TEST
WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING WITH COOLANT PRESSURE CAP
REMOVED.
VISUAL TEST METHOD
With the engine cool, remove the coolant pressure cap. Start the engine andallow it to warm up until thermostat
opens.
If a large combustion/compression pressure leak exists, bubbles will be visible in the coolant.
COOLING SYSTEM TESTER METHOD
WARNING: WITH COOLING SYSTEM TESTER IN PLACE, PRESSURE WILL BUILD UP FAST.EXCESSIVE
PRESSURE BUILT UP, BY CONTINUOUS ENGINE OPERATION, MUST BE RELEASED TO A SAFE PRESSURE
POINT. NEVER PERMIT PRESSURE TO EXCEED 138 kPa (20 psi).

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.

17. Install the intake manifold.
18. Using a new gasket, install throttle body (Refer to
14 - FUEL SYSTEM/FUEL INJECTION/THROT-
TLE BODY - INSTALLATION).
19. Install the generator (2) and wire connections
(Refer to 8 - ELECTRICAL/CHARGING/GENERA-
TOR - INSTALLATION).
20. Install a/c compressor (2) (Refer to 24 - HEATING
& AIR CONDITIONING/PLUMBING/A/C COM-
PRESSOR - INSTALLATION).

CYLINDER HEAD
OPERATION—CYLINDER HEAD
The cylinder head closes the combustion chamber allowing the pistons to compress the air fuel mixture to the cor-
rect ratio for ignition. The valves located in the cylinder head open and close to either allow clean air into the com-
bustion chamber or to allow the exhaust gases out, depending on the stroke of the engine.
DIAGNOSIS AND TESTING—CYLINDER HEAD GASKET FAILURE
A cylinder head gasket leak can be located between adjacent cylinders or between a cylinder and the adjacent
water jacket.
Possible indications of the cylinder head gasket leaking between adjacent cylinders are:
− Loss of engine power
− Engine misfiring
− Poor fuel economy
Possible indications of the cylinder head gasket leaking between a cylinder and an adjacent water jacket are:
− Engine overheating
− Loss of coolant
− Excessive steam (white smoke) emitting from exhaust
− Coolant foaming
CYLINDER-TO-CYLINDER LEAKAGE TEST
To determine if an engine cylinder head gasket is leaking between adjacentcylinders, follow the procedures in Cyl-
inder Compression Pressure Test in this section. An engine cylinder head gasket leaking between adjacent cylinders
will result in approximately a 50–70% reduction in compression pressure.
CYLINDER-TO-WATER JACKET LEAKAGE TEST
WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING WITH COOLANT PRESSURE CAP
REMOVED.
VISUAL TEST METHOD
With the engine cool, remove the coolant pressure cap. Start the engine andallow it to warm up until thermostat
opens.
If a large combustion/compression pressure leak exists, bubbles will be visible in the coolant.
COOLING SYSTEM TESTER METHOD
WARNING: WITH COOLING SYSTEM TESTER IN PLACE, PRESSURE WILL BUILD UP FAST.EXCESSIVE
PRESSURE BUILT UP, BY CONTINUOUS ENGINE OPERATION, MUST BE RELEASED TO A SAFE PRESSURE
POINT. NEVER PERMIT PRESSURE TO EXCEED 138 kPa (20 psi).
Install Cooling System Tester 7700 or equivalent to pressure cap neck. Start the engine and observe the tester’s
pressure gauge. If gauge pulsates with every power stroke of a cylinder a combustion pressure leak is evident.
CHEMICAL TEST METHOD
Combustion leaks into the cooling system can also be checked by using Bloc-Chek Kit C-3685-A or equivalent.
Perform test following the procedures supplied with the tool kit.

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).

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).