DODGE RAM SRT-10 2006 Service Repair Manual

DESCRIPTION Nꞏm Ft. Lbs. In. Lbs.
Bolts-Turbocharger Oil Drain Tube-(Diesel) 24 18 -
Fitting-Turbocharger Oil Supply Line-(Diesel) 36 27 -
Nut-Turbocharger V-Band Clamp Cast Elbow to Turbocharger-
(Diesel)8-75
Nut-T-bolt Clamp Cast Elbow to Exhaust pipe-(Diesel) NOTE:
This is a One Time Use Only Nut.11 - 1 0 0
Turbocharger Oil Supply fitting at Turbocharger-(Diesel) 36 27 -
Turbocharger Oil Supply fitting at lube filter head-(Diesel) 24 18 -

SPECIAL TOOLS
TURBOCHARGER TESTER 9022

CONVERTER-CATALYTIC
DESCRIPTION
WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THERE-
FORE, NEVER WORK AROUND OR ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEMUNTIL IT
IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER.
THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OFENGINE
OPERATION TIME.
CAUTION: DO NOT remove spark plug wires from plugs or by any other means short out cylinders. Failure
of the catalytic converter can occur due to a temperature increase caused by unburned fuel passing
through the converter.
The stainless steel catalytic converter body is designed to last the life of the vehicle. Excessive heat can result in
bulging or other distortion, but excessive heat will not be the fault of theconverter. If unburned fuel enters the con-
verter, overheating may occur. If a converter is heat-damaged, correct the cause of the damage at the same time
the converter is replaced. Also, inspect all other components of the exhaust system for heat damage.
Unleaded gasoline must be used to avoid contaminating the catalyst core.
50 State emission vehicles incorporate two mini catalytic converters located after the exhaust manifolds and before
the inline catalytic converter.
OPERATION
The catalytic converter captures and burns any unburned fuel mixture exiting the combustion chambers during the
exhaust stroke of the engine. This process aids in reducing emissions output.
REMOVAL
3.7L/4.7L ENGINE
1. Raise and support vehicle.
2. Saturate the bolts and nuts with heat valve lubri-
cant. Allow 5 minutes for penetration.
3. Disconnect oxygen sensor electrical connectors.
4. Remove clamp (4).
5. Remove bolts exhaust to manifold (2).
6. Remove catalytic converter (3).

5.7L ENGINE
1. Raise and support vehicle.
2. Saturate the bolts and nuts with heat valve lubri-
cant. Allow 5 minutes for penetration.
3. Disconnect oxygen sensor electrical connectors.
4. Remove clamps and nuts (4).
5. Remove catalytic converter to exhaust manifold
bolts (2) and nuts (1).
6. Remove catalytic converter assembly (3).
5.9L DIESEL ENGINE
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
1. Raise and support the vehicle.
2. Saturate the bolts and nuts with heat valve lubri-
cant. Allow 5 minutes for penetration.
3. Remove clamp bolts from exhaust pipe to catalytic
converter clamp (5).
NOTE: Do not remove nut from T-Bolt. Only
remove nut far enough, so that the T-end can be
removed from the clamp.
NOTE: The catalytic converter to exhaust manifold
clamp is not reusable. Always use a new clamp
when reinstalling the catalytic converter.
4. Loosen the nut from clamp (1) at turbocharger.
5. Remove the T-bolt end of the fastener, from the
clamp (1).
6. Spread the clamp, and remove the catalytic converter (4) and front exhaust pipe (2) from the vehicle.
7. Discard the clamp.
8. Remove front exhaust pipe to catalytic converter clamp (3).
9. Separate front exhaust pipe (2) from catalytic converter (4).

8.3L ENGINE
1. Raise and support vehicle.
2. Saturate the bolts and nuts with heat valve lubri-
cant. Allow 5 minutes for penetration.
3. Disconnect oxygen sensor electrical connectors.
4. Remove LH exhaust pipe to manifold bolts (2),
retainers and nuts (1).
5. Remove LH catalytic converter to muffler clamp
nuts (4).
6. Rotate LH catalytic converters (6) from the muffler
(5).
7. Remove RH exhaust pipe to manifold bolts (2),
retainers and nuts (1).
8. Remove RH catalytic converter to muffler clamp
nuts (4).
9. Rotate RH catalytic converter (3) from the muffler
(5).
10. Remove clamps and nuts (4).
INSPECTION
Look at the stainless steel body of the converter, inspect for bulging or other distortion that could be a result of
overheating. If the converter has a heat shield attached make sure it is notbent or loose.
If you suspect internal damage to the catalyst, tapping the bottom of the catalyst with a rubber mallet may indicate
a damaged core.
INSTALLATION
3.7L/4.7L ENGINE
1. Install RH catalytic converter to exhaust clamp (4)
on RH catalytic converter (3) and position into
exhaust pipe (5).
2. Install and hand tighten RH catalytic converter to
exhaust manifold bolts (2).
3. Install c-clip nut (1) and bolt (2) to converter (3) to
manifold.
4. Tighten catalytic converter to exhaust manifold
bolts(1)to31Nꞏm(23ft.lbs.).
5. Tighten all clamp nuts (4) to 52.2 Nꞏm (40 ft. lbs.)
torque.
6. Check the exhaust system for contact with the
body panels. A minimum of 25 mm (1.0 in.) is
required between the exhaust system components
and body/frame parts. Make the necessary adjust-
ments, if needed.
7. Check to ensure you have at least 25 mm clear-
ance to oil pan.
8. Plug in O2 sensor wiring.
9. Lower the vehicle.
10. Start the engine and inspect for exhaust leaks. Repair exhaust leaks asnecessary.

5.7L ENGINE
1. Install catalytic converter to exhaust clamp (4) on
catalytic converter (3) and position into exhaust
pipe (5).
2. Make sure the alignment tang on catalytic con-
verter (3) is fully seated in the notch on the
exhaust pipe (5).
3. Install catalytic converter to exhaust manifold bolts
(2) and nuts (1).
4. Tighten catalytic converter to exhaust manifold
bolts(2)to31Nꞏm(23ft.lbs.).
5. Tighten catalytic converter to exhaust pipe clamp
nuts (4) to 52 Nꞏm (40 ft. lbs.) torque.
6. Check the exhaust system for contact with the
body panels. A minimum of 25 mm (1.0 in.) is
required between the exhaust system components
and body/frame parts. Make the necessary adjust-
ments, if needed.
7. Lower the vehicle.
8. Start the engine and inspect for exhaust leaks.
Repair exhaust leaks as necessary.
5.9L ENGINE DIESEL
NOTE: The catalytic converter to Front exhaust
pipe clamp is not reusable. Always use a new
clamp when reinstalling the catalytic converter.
NOTE: The Front exhaust pipe to Elbow clamp is
not reusable. Always use a new clamp when rein-
stalling the Front exhaust pipe.
1. Position the catalytic converter (4) onto the front
exhaust pipe (2) until the alignment tab is seated
into the alignment slot of the catalytic converter (4).
2. Install catalytic converter (4) into the exhaust pipe
(6) until the alignment tab is seated into the align-
ment slot of exhaust pipe (6).
3. Position front exhaust pipe (2) onto turbocharger
and install new clamp (1). Tighten the nuts to 11
Nꞏm (100 in. lbs.) torque.
4. Install the exhaust clamp (5) at the exhaust pipe
(6) and catalytic converter (4) connection. Tighten
the clamp nuts to 54 Nꞏm (40 ft. lbs.) torque.
5. Check the exhaust system for contact with the
body panels. A minimum of 25 mm (1.0 in.) is required between the exhaust system components and body/frame
parts. Make the necessary adjustments, if needed.
6. Lower the vehicle.
7. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary.

8.3L ENGINE
1. Make sure catalytic converters (3, 6) and mufflers
(5) are free of burrs.
2. Insert RH catalytic converter (3) into muffler (5).
3. Make sure the alignment tang on the catalytic con-
verter (3) seats in the alignment slot on the muffler
(5).
4. Position the catalytic converter (3) to the exhaust
manifold. Install and hand tighten bolts (2) , retain-
ers and nuts (1).
5. Insert LH catalytic converter (6) into muffler (5).
6. Make sure the alignment tang on the catalytic con-
verter (6) seats in the alignment slot on the muffler
(5).
7. Position the catalytic converter (6) to the exhaust
manifold. Install and hand tighten bolts (2), retain-
ers and nuts (1).
8. Check the exhaust system for contact with the
body panels. A minimum of 25 mm (1.0 in.) is
required between the exhaust system components and body/frame parts. Clearance between catalytic converter
and frame is 15 mm (.59 inch). Make the necessary adjustments, if needed.
9. Tighten catalytic converter to exhaust manifold bolts (2) to 20 Nꞏm (15 ft. lbs.) torque.
10. Tighten the clamp nuts to 54 Nꞏm (40 ft. lbs.) torque.
11. Lower the vehicle.
12. Start the engine and inspect for exhaust leaks. and exhaust system. Repair exhaust leaks as necessary.

PIPE EXHAUST
REMOVAL
3.7L/4.7L/5.7L ENGINE
1. Raise and support the vehicle.
2. Saturate the bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration.
3. Remove exhaust pipe to manifold bolts and nuts.
4. Remove the clamp nuts.
5. Remove the exhaust pipe.
5.9L DIESEL
1. Disconnect the battery negative cables.
2. Raise and support the vehicle on a hoist.
3. Saturate the bolts and nuts with heat valve lubri-
cant. Allow 5 minutes for penetration.
4. Remove the exhaust pipe-to-extension pipe clamp.
Separate the exhaust pipe and extension pipe.
5. Remove the exhaust pipe-to-turbocharger elbow
clamp and discard.
6. Remove the exhaust pipe from the transmission
support.
8.3L ENGINE
1. Raise and support the vehicle.
2. Saturate the bolts and nuts with heat valve lubri-
cant. Allow 5 minutes for penetration.
3. Remove clamp nuts.
4. Remove exhaust pipe isolators.
5. Rotate the exhaust pipes to remove from the
muffle.

INSPECTION
Discard rusted clamps, broken or worn supports and attaching parts. Replace a component with original equipment
parts, or equivalent. This will assure proper alignment with other parts in the system and provide acceptable exhaust
noise levels.
INSTALLATION
3.7L/4.7L/5.7L ENGINE
1. Position the exhaust pipe for proper clearance with the frame and underbody parts. A minimum clearance of 25
mm (1.0 in.) is required.
2. Position the exhaust pipe to manifold. Install the bolts and nuts. Tighten the nuts to 31 Nꞏm (23 ft. lbs.) torque.
3. Tighten the clamp nuts to 54 Nꞏm (40 ft. lbs.) torque.
4. Lower the vehicle.
5. Start the engine and inspect for exhaust leaks and exhaust system contact with the body panels. Adjust the
alignment, if needed.
5.9L DIESEL
1. Install the exhaust pipe into the transmission sup-
port and onto the turbocharger flange.
2. Install a New exhaust pipe-to-turbocharger elbow
clamp and tighten to 11 Nꞏm (100 in. lbs.) torque.
3. Install the extension pipe and clamp to the exhaust
pipe using a new clamp and tighten the clamp nuts
to 54 Nꞏm (40 ft. lbs.) torque.
4. Check the exhaust system for contact with the
body panels. A minimum of 25 mm (1.0 in.) is
required between the exhaust system components
and body/frame parts. Make the necessary adjust-
ments, if needed.
5. Lower the vehicle.
6. Connect the battery negative cables.
7. Start the engine and inspect for exhaust leaks.
Repair exhaust leaks as necessary.

8.3L ENGINE
1. Make sure exhaust pipe is free of any burrs.
2. Insert exhaust pipes into muffler.
3. Make sure alignment tang on exhaust pipes seat
into alignment slot on muffler.
4. Install exhaust pipe insulators.
5. Position the exhaust pipe for proper clearance with
the frame and underbody parts. A minimum clear-
ance of 25 mm (1.0 in.) is required.
6.Tightentheclampnutsto54Nꞏm(40ft.lbs.)
torque.
7. Lower the vehicle.
8. Start the engine and inspect for exhaust leaks and
inspect for exhaust leaks. Repair exhaust leaks as
necessary.