DODGE RAM SRT-10 2006 Service Repair Manual

INSPECTION
1. The crankshaft journals should be checked for excessive wear, taper andscoring. Limits of taper or out-of-round
on any crankshaft journals should be held to 0.025 mm (0.001 in.). Journal grinding should not exceed 0.508 mm
(0.020 inch) under the standard journal diameter. DO NOT grind thrust faces of No. 3 main bearing. DO NOT
nick crank pin or bearing fillets. After grinding, remove rough edges fromcrankshaft oil holes and clean out all
passages.
CAUTION: With the forged crankshafts it is important that the final paper or cloth polish after any journal
regrind be in the same direction as normal rotation in the engine.
2. Check and clean all oil holes for blockage and debris.
INSTALLATION
1. Install upper main bearing shells into engine block.
2. Lubricate upper main bearing shells with clean
engine oil.
3. Install the crankshaft.
4. Install lower main bearing shells into main bearing
caps.
5. Install each main bearing cap in proper sequence
and direction (1). Tighten all bolts finger tight.

6. Tighten the main cap bolts following the illustrated tightening sequence:
Step 1Tighten main bearing cap bolts 1-12 inthe illustrated sequence to 20 Nꞏm (15 ft. lbs.). This will seat the
bearing caps onto the engine block.
Step 2To ensure correct thrust bearing alignment the following procedure must be follwed:
a. Move crankshaft all the way to the rear of its travel.
b. Then, move crankshaft all the way to the front of its travel.
c. Wedge an appropriate tool between the rear of the cylinder block and rearcrankshaft counterweight.
This will hold the crankshaft in it’s most forward position.
Step A1–tighten the A1 bolts to 61 Nꞏm (45 ft. lbs.) in the illustrated sequence.
Step A2–tighten the A2 bolts to 115 Nꞏm (85 ft. lbs.) in the illustrated sequence.
Step A3–tighten the A3 Bolts to 54 Nꞏm (40 ft. lbs.) in the illustrated sequence.
7. Remove the holding tool.
8. Install new connecting rod bearings.
9. Install rod caps. InstallNEWconnecting rod bolts. Bolt threads should be oiled with engine oil. Torqueconnecting
rod bolts to 68 Nꞏm (50 ft. lbs.).

10. Install the crankshaft oil scraper and tighten nuts
to 23 Nꞏm (200 in. lbs.).
11.Installoilpumppickuptube(2)usinganew
o-ring (4). Torque 1/4-20 bolt to 11 Nꞏm (95 in.
lbs.). Torque 5/16-18 nuts to 23 Nꞏm (200 in. lbs.).
12. Install the crankshaft rear oil seal and retainer
(Refer to 9 - ENGINE/ENGINE BLOCK/CRANK-
SHAFT REAR OIL SEAL RETAINER - INSTALLA-
TION).
13. Install lower crankshaft gear along with the timing
chain (Refer to 9 - ENGINE/VALVE TIMING/TIM-
ING CHAIN AND SPROCKETS - INSTALLA-
TION).
14. Install timing chain cover (Refer to 9 - ENGINE/
VALVE TIMING/TIMING CHAIN COVER(S) -
INSTALLATION).
15. Install oil pan (Refer to 9 - ENGINE/LUBRICA-
TION/OIL PAN - INSTALLATION).
16. Install crankshaft damper and pulley (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
INSTALLATION).
17. Install engine assembly (Refer to 9 - ENGINE -
INSTALLATION).

BEARING-CRANKSHAFT PILOT
REMOVAL
1. Remove transmission (Refer to 21 - TRANSMIS-
SION/TRANSAXLE/MANUAL - REMOVAL).
2. Remove clutch and flywheel (Refer to 6 - CLUTCH/
CLUTCH DISC - REMOVAL).
3. Using Special Tools 8990 (1) and C-3752 (2),
remove pilot bearing from crankshaft.
INSTALLATION
NOTE: New pilot bearing has special grease
packed into bearing. Do not wash grease from
bearing. Install bearing with part number markings
(1) facing out.

1. Install pilot bearing with Special Tools 9058 (1) and
C-4171 (2).
2. Install flywheel and clutch (Refer to 6 - CLUTCH/
CLUTCH DISC - INSTALLATION).
3. Install transmission (Refer to 21 - TRANSMISSION/
TRANSAXLE/MANUAL - INSTALLATION).

EXHAUST SYSTEM
TABLE OF CONTENTS
page page
EXHAUST SYSTEM
DESCRIPTION
GAS ENGINES ............................... 2
5.9L DIESEL ................................. 3
DIAGNOSIS AND TESTING
GAS ENGINE ................................ 4
DIESEL ENGINE............................. 5
SPECIFICATIONS
TORQUE .................................... 5
SPECIAL TOOLS ............................... 7
CONVERTER-CATALYTIC
DESCRIPTION ................................. 8
OPERATION ................................... 8
REMOVAL
3.7L/4.7L ENGINE ............................ 8
5.7L ENGINE ................................ 9
5.9L DIESEL ENGINE ......................... 9
8.3L ENGINE ............................... 10
INSPECTION ................................. 10
INSTALLATION
3.7L/4.7L ENGINE ........................... 10
5.7L ENGINE ............................... 11
5.9L ENGINE DIESEL ........................ 11
8.3L ENGINE ............................... 12
PIPE EXHAUST
REMOVAL
3.7L/4.7L/5.7L ENGINE ...................... 13
5.9L DIESEL ................................ 13
8.3L ENGINE ............................... 13
INSPECTION ................................. 14
INSTALLATION
3.7L/4.7L/5.7L ENGINE ...................... 14
5.9L DIESEL ................................ 14
8.3L ENGINE ............................... 15
HEAT SHIELDS
DESCRIPTION ................................ 16
REMOVAL .................................... 16
INSTALLATION ............................... 17
MUFFLER
REMOVAL
3.7L/4.7L/5.7L ENGINE ...................... 19
8.3L ENGINE ............................... 195.9L DIESEL ENGINE....................... 20
INSTALLATION
3.7L/4.7L/5.7L ENGINE ...................... 20
8.3L ENGINE ............................... 21
5.9L DIESEL ENGINE....................... 21
TAILPIPE
REMOVAL
3.7L/4.7L/5.7L ENGINE ...................... 22
5.9L DIESEL................................ 22
8.3L ENGINE ............................... 23
INSPECTION ................................. 23
INSTALLATION
3.7L/4.7L/5.7L ENGINE ...................... 23
5.9L DIESEL................................ 24
8.3L ENGINE ............................... 24
TURBOCHARGER SYSTEM
DIAGNOSIS AND TESTING
TURBOCHARGER BOOST PRESSURE ....... 25
TURBOCHARGER
DESCRIPTION ................................ 26
OPERATION .................................. 27
REMOVAL
TURBOCHARGER .......................... 29
TURBOCHARGER OIL DRAIN TUBE .......... 30
CLEANING ................................... 30
INSPECTION ................................. 30
INSTALLATION
TURBOCHARGER .......................... 31
TURBOCHARGER OIL DRAIN TUBE .......... 32
WASTEGATE - ELECTRONIC ACTUATOR
REMOVAL .................................... 33
INSTALLATION ............................... 33
CHARGE AIR COOLER AND PLUMBING
DESCRIPTION ................................ 34
OPERATION .................................. 34
DIAGNOSIS AND TESTING
CHARGE AIR COOLER SYSTEM - LEAKS.... 35
REMOVAL .................................... 35
CLEANING ................................... 36
INSPECTION ................................. 36
INSTALLATION ............................... 36

EXHAUST SYSTEM
DESCRIPTION
GAS ENGINES
CAUTION: Avoid application of rust prevention compounds or undercoatingmaterials to exhaust system
floor pan exhaust heat shields. Light overspray near the edges is permitted. Application of coating will
result in excessive floor pan temperatures and objectionable fumes.
The federal gasoline engine exhaust system consists of engine exhaust manifolds, exhaust pipes, catalytic convert-
er(s), extension pipe (if needed), exhaust heat shields, muffler and exhaust tailpipe ,.
The California emission vehicles exhaust system also contains the above components as well as mini catalytic con-
verters added to the exhaust pipe.

The exhaust system must be properly aligned to prevent stress, leakage andbody contact. Minimum clearance
between any exhaust component and the body or frame is 25.4 mm (1.0 in.). If the system contacts any body panel,
it may amplify objectionable noises from the engine or body.
5.9L DIESEL
CAUTION: Avoid application of rust prevention compounds or undercoatingmaterials to exhaust system
floor pan exhaust heat shields. Light overspray near the edges is permitted. Application of coating will
result in excessive floor pan temperatures and objectionable fumes.
The diesel engine exhaust system consists of an engine exhaust manifold, turbocharger, exhaust pipe, resonator,
extension pipe, catalytic converter, muffler and exhaust tailpipe.
The exhaust system must be properly aligned to prevent stress, leakage andbody contact. The exhaust compo-
nents should be kept a minimum of 25.4 mm (1.0 in.) away from the body and frame. If the system contacts any
body panel, it may amplify objectionable noises from the engine or body.

DIAGNOSIS AND TESTING
GAS ENGINE
EXHAUST SYSTEM DIAGNOSIS CHART
CONDITION POSSIBLE CAUSE CORRECTION
EXCESSIVE EXHAUST NOISE OR
LEAKING EXHAUST GASES1. Leaks at pipe joints. 1. Tighten clamps/bolts at leaking
joints.
2. Rusted or blown out muffler. 2. Replace muffler. Inspect exhaust
system.
3. Broken or rusted out exhaust
pipe.3. Replace exhaust pipe.
4. Exhaust pipe leaking at manifold
flange.4. Tighten/replace flange attaching
nuts/bolts.
5. Exhaust manifold cracked or
broken.5. Replace exhaust manifold.
6. Leak between exhaust manifold
and cylinder head.6. Tighten exhaust manifold to
cylinder head bolts.
7. Catalytic converter rusted or
blown out.7. Replace catalytic converter assy.
8. Restriction in exhaust system. 8. Remove restriction, if possible.
Replace restricted part if necessary.
CAUTION:
When servicing and replacing exhaust system components, disconnect the oxygen sensor connector(s). Allowing
the exhaust to hang by the oxygen sensor wires will damage the harness and/or sensor.

DIESEL ENGINE
EXHAUST SYSTEM DIAGNOSIS CHART
CONDITION POSSIBLE CAUSE CORRECTION
EXCESSIVE EXHAUST NOISE OR
LEAKING EXHAUST GASES1. Leaks at pipe joints. 1. Tighten clamps/bolts at leaking
joints.
2. Rusted or blown out muffler. 2. Replace muffler. Inspect exhaust
system.
3. Broken or rusted out exhaust
pipe.3. Replace exhaust pipe.
4. Exhaust pipe leaking at manifold
flange.4. Tighten/replace flange attaching
nuts/bolts.
5. Exhaust manifold cracked or
broken.5. Replace exhaust manifold.
6. Leak between exhaust manifold
and cylinder head.6. Tighten exhaust manifold to
cylinder head bolts. Replace gasket
if necessary.
7. Turbocharger mounting flange
cracked.7. Remove turbocharger and
inspect. (Refer to 11 - EXHAUST
SYSTEM/TURBOCHARGER
SYSTEM/TURBOCHARGER -
REMOVAL).
8. Restriction in exhaust system. 8. Remove restriction, if possible.
Replace restricted part if necessary.
SPECIFICATIONS
TORQUE
DESCRIPTION Nꞏm Ft. Lbs. In. Lbs.
Bolt-Adjusting Strap 23 - 200
Nuts-Air Heater Power Supply 14 - 124
Bolts-Air Inlet Housing 24 18 -
Nuts-Cab Heater Supply/Return Line 24 18 -
Nuts-Exhaust Clamp 54 40 -
Bolts-Exhaust Manifold to Cylinder Head - (Diesel) 43 32 -
Bolts-Exhaust Manifold to Cylinder Head - (Diesel) 31 23 -
Bolts-Exhaust Manifold to Cylinder Head-(8.3L) 22 - 195
Bolts-Exhaust Pipe to Manifold 31 23 -
Bolts-Generator Mounting 41 30 -
Bolts-Charge Air Cooler Mounting 10 - 90
Nuts-Charge Air Cooler Duct 11 - 95
Bolt-Generator to Block-Diesel 24 18 -
Nuts and Bolts-Heat Shield 11 - 95
Nuts-Heat Shield-Diesel 24 18 -
Electronically Controlled Wastegate Command Valve-(Diesel) 34 25 -
Turbocharger flange studs-(Diesel) 24 18 -
Nuts-Turbocharger Mounting-(Diesel) 43 32 -