fuel cap DODGE RAM SRT-10 2006 Service Owner's Manual

12. Place a rag over the compression test tool fitting. Crank the engine for2–3 seconds to purge any fuel that may
have drained into the cylinder when the injector was removed.
13. Connect the compression test gauge.
14. Crank the engine for 5 seconds and record the pressure reading. Repeat this step three times and calculate the
average of the three readings.
NOTE: The minimum cylinder pressure is 350 psi. Cylinder pressure should be within 20% from cylinder to
cylinder.
15. Combustion pressure leakage can be checked if cylinder pressure is below the specification. Perform the leak-
age test procedure on each cylinder according to the tester manufacturer instructions.
16. Upon completion of the test check and erase any engine related fault codes.
CYLINDER COMBUSTION PRESSURE LEAKAGE
The combustion pressure leakage test provides an accurate means for determining engine condition.
Combustion pressure leakage testing will detect:
Exhaust and intake valve leaks (improper seating).
Leaks between adjacent cylinders or into water jacket.
Any causes for combustion/compression pressure loss
1. Start and operate the engine until it attains normal operating temperature.
2. Disconnect injector harness connectors.
3. Disconnect breather tube and breather drain tube from valve cover.
4. Remove the cylinder head cover. (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) -
REMOVAL)
5. Disconnect harness from injectors.
6. Remove the cylinder head cover carrier gasket. (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL)
7. BringthecylindertobetestedtoTDC.
8. Remove the high pressure fuel line between the cylinder head and the fuelrail for the cylinder to be tested.
9. Install capping Tool 9011 onto the rail.
10. Remove the high pressure connector nut and high pressure connector with Tool 9015.
11. Remove the exhaust and intake rocker lever.
12. Use Tool # 9010 to remove the injector and copper sealing washer.
13. Install compression test Tool # 9007 into the injector bore.
14. Connect the leakage tester and perform the leakage test procedure on each cylinder according to the tester
manufacturer’s instructions.
15. Upon completion of the test check and erase any engine related fault codes.
STANDARD PROCEDURE
STANDARD PROCEDURE - FORM-IN-PLACE GASKETS AND SEALERS
There are numerous places where form-in-place gaskets are used on the engine. Care must be taken when apply-
ing form-in-place gaskets to assure obtaining the desired results.Do not use form-in-place gasket material
unless specified.Bead size, continuity, and location are of great importance. Too thin a bead can result in leakage
while too much can result in spill-overwhich can break off and obstruct fluid feed lines. A continuous bead of the
proper width is essential to obtain a leak-free gasket.
There are numerous types of form-in-place gasket materials that are used in the engine area. Mopar
Engine RTV
GEN II, Mopar
ATF-RTV, and MoparGasket Maker gasket materials, each have different properties and can not
be used in place of the other.
MOPAR
ENGINE RTV GEN II

NOTE: Extreme care should be used to keep dirt/debris from entering the fuel lines. Plastic caps should be
used on the ends of the fuel lines.
46. Loosen # 6 fuel line shield bolts and rotate shield out of the way.
47. Remove cylinder # 5 and # 6 high pressure fuel lines.
48. Remove the rear engine lift bracket.
49. Remove cylinder # 4, # 5, and # 6 intake and
exhaust rocker arms (1), pedestals (2), and push
tubes. Note the original location for reassembly.
50. Remove the fuel connector tube nut and fuel con-
nector tube. Remove cylinder # 5 and # 6 fuel
injector.
51. Remove rocker housing.
52. Remove two cylinder head bolts (1) according to
the diagram and install Tool # 9009 (2). Torque
bolts to 105 Nꞏm (77 ft. lbs.).
53. Loosen but do not remove engine mount through
bolts and nuts.
54. Disconnect hood support struts and position hood
out of the way.
55. Attach a chain with two hooks to the engine lift
brackets.
56. While keeping engine level, lift straight up out of
the mounts.
57. Rotate nose of engine upward and pull out of
chassis.

INSTALLATION - ENGINE
1. Remove cylinder head bolts (1,3) according to the
diagram. Install special Tool 9009 (2). Torque bolts
to 105 Nꞏm (77 ft. lbs.)
2. Lower engine into the engine compartment and
install the engine mount through bolts and nuts.
3. Tighten the mount through bolts and nuts to 88
Nꞏm (65 ft. lbs) torque.
4. Remove the engine lifting device (Tool 9009).
5. Check cylinder head capscrew length and install
into cylinder head.
6. Torque in 4 steps to:
Step 1—Tighten to 70 Nꞏm (52 ft. lbs.) torque.
Step 2—Back off 360°.
Step 3—Tighten to 105 Nꞏm (77 ft. lbs.) torque.
Step 4—Rotate 90°.
7. Install rocker housing. Torque to 24 Nꞏm (18 ft. lbs). Refer to (Refer to 9- ENGINE/CYLINDER HEAD/CYLINDER
HEAD COVER(S) - INSTALLATION).
8. Replace injector o-ring and sealing washer on injectors # 5 and # 6. Install injectors and torque using the fol-
lowing steps:
Step 1—Install injector hold-down capscrews and torque to 5 Nꞏm (44 in. lbs.) torque.
Step 2—Loosen injector hold-down capscrews.
Step 3—Install HPC connector tube and nut. Torque nut to 15 Nꞏm (11 ft. lbs.)torque.
Step 4—Torque injector hold-down capscrews to 10 Nꞏm (89 in. lbs.) torque.
Step 5—Torque HPC connector tube nut to 50 Nꞏm (37 ft. lbs.) torque.
9. Install rear engine lift bracket. Torque to 77 Nꞏm (57 ft. lb).
10. Install # 5 and # 6 high pressure fuel lines. Follow correct torque sequence per section 14. Torque fuel line
fittings to 30 Nꞏm (22 ft. lb). Torque brace capscrew and nut to 24 Nꞏm (18 ft.lb).
11. Install push tubes, rocker arms (1), and pedestals
(2) for cylinders # 4, # 5, and # 6. Torque the
mounting bolts to 36 Nꞏm (27 ft. lbs).
12. Reset valve lash on cylinders # 4, # 5, and # 6.
Torque adjusting nuts to 24 Nꞏm (18 ft. lbs).
13. Install injector wiring/gasket.

DESCRIPTION Nꞏm In. Lbs. Ft. Lbs.
Connecting Rod—Bolts
Step 1 30 — 22
Step 2 60 — 44
Step 3 Rotate 60 degrees
Crankshaft Main Cap—Bolts
Step 1 50 37
Step 2 80 59
Step 3 Rotate 90°
Cylinder Head—Bolts
Step 1 70 — 52
Step 2 Back off 360 degrees
Step 3 105 — 77
Step 4 Verify 105 — 77
Step 5 Rotate All Bolts 1/4 Turn
Cylinder Head Cover Bolts 24 — 18
Breather Cover Bolts 24 — 18
HPC Nut 50 — 37
Flexplate to Engine 137 — 101
Flywheel to Engine ( NV 5600 ) 137 — 101
Flywheel/Crankshaft Adapter 137 — 101
G 56 Dual Mass Flywheel
Fuel Delivery Lines—Banjo 24 — 18
Fuel Drain Line—Banjo 24 — 18
Fuel line—rail to cylinder head 30 — 22
Fuel line—pump to fuel rail 37 — 27
Injector fuel line brace 24 — 18
#6 Fuel Line Brace Nut at Lift Bracket Stud 24 — 18
Fuel rail holddown bolt 24 — 18
Oil Pan—Bolts 28 — 21
Oil Pan—Drain Plug 50 — 37
Oil Pressure Regulator—Plug 80 — 59
Oil Pressure Switch 18 — 13
Oil Pump—Bolts
Step1 8 — 6
Step2 24 — 18
Oil Suction Tube (Flange)—Bolts 24 — 18
Oil Suction Tube (Brace)—Bolt 43 — 32
Rocker Arm/Pedestal—Bolts 36 — 27

CYLINDER HEAD
DESCRIPTION
The cylinder head is constructed of cast iron and is a one piece cross flow design with four valves per cylinder. The
arrangement of two intake and two exhaust valves per cylinder allows for a centrally located injector. The cylinder
head also includes an integral intake manifold, an integral thermostat housing, and a longitudal fuel return rifle,
which exits at the rear of the head. The 24 valve design also includes integrally cast valve guides and hardened
intake and exhaust valve seat inserts.
REMOVAL
1. Disconnect battery negative cables.
2. Raise vehicle on hoist.
3. Drain engine coolant.
4. Disconnect exhaust pipe from turbocharger elbow.
5. Remove turbocharger drain tube bolts at turbocharger. Cap off ports to prevent dirt or foreign material from enter-
ing.
6. Lower vehicle.
7. Disconnect air inlet temperature/pressure sensor.
8. Remove air cleaner housing and snorkel from the vehicle. Cap off turbocharger air inlet to prevent intrusion of
dirt or foreign material.
9. Disconnect cab heater core supply and return hoses from the cylinder head and heater pipe.
10. Disconnect turbocharger oil supply line at the turbocharger end. Cap off open ports to prevent intrusion of dirt
or foreign material.
11. Remove exhaust manifold-to-cylinder head bolts, spacers, heat shield, retention straps, and cab heater plumb-
ing. Remove exhaust manifold and turbocharger from the vehicle as an assembly.
12. Remove cooling fan/drive/shroud assembly. (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - REMOVAL)
13. Remove accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
14. Remove cooling fan support from cylinder block.
15. Remove upper generator bolt, loosen lower generator bolt, and rotate generator away from cylinder head.
16. Disconnect radiator upper hose from the thermostat housing.
17. Disconnect the Intake Air Temperature/Manifold Air Pressure, and Coolant Temperature sensor connectors.
18. Remove the engine harness to cylinder head attaching bolts and P-clipsat front of head.
19. Remove the intake air grid heater wires from the grid heater.
20. Remove engine oil level indicator tube attaching bolt at fuel filter housing bracket and inlet air connection..
21. Remove the charge air cooler-to-air inlet housing pipe.
22. Remove the engine wire harness attaching bolt and wire harness push-infastener from air inlet housing.
23. Remove the air inlet housing and intake grid heater from the intake manifold cover.
24. Remove the two grid heater harness-to-cylinder head attaching bolts at front of cylinder head.
NOTE: Extreme care should be used to keep dirt/debris from entering the fuel lines. Plastic caps should be
used on the ends of the fuel lines.
25.Remove the high pressure pump to fuel rail fuel line as follows:
a. Loosen fuel line nuts at fuel pump and at fuel rail.
b. Use a back-up wrench on the fitting at the fuel pump to keep it from loosening.
26. Remove the fuel rail to cylinder head fuel lines as follows:
a. Loosen No. 6 high pressure fuel line shield and position out of way.
b. Loosen the fuel line nuts at the fuel rail and at the cylinder head. Use a back-up wrench on HPC nut.
c. Remove the fuel line bracket bolts at the intake manifold cover.

OIL
STANDARD PROCEDURE
STANDARD PROCEDURE - ENGINE OIL LEVEL
CAUTION: Do not overfill crankcase with engine
oil, oil foaming and oil pressure loss can result.
To ensure proper lubrication of an engine, the engine
oil must be maintained at an acceptable level. The
acceptable oil level is in the SAFE RANGE (3) on the
engine oil dipstick.
1. Position vehicle on level surface.
2. With engine OFF, allow approximately 15 minutes
for oil to settle to bottom of crankcase, remove
engine oil dipstick.
3. Wipe dipstick clean.
4. Replace dipstick and verify it is seated in the tube.
5. Remove dipstick, with handle held above the tip, take oil level reading.
6. Add oil only if level is below the SAFE RANGE area on the dipstick.
7. Replace dipstick.
STANDARD PROCEDURE - ENGINE OIL SERVICE
WARNING: HOT OIL CAN CAUSE PERSONAL INJURY.
NOTE: Change engine oil and filter at intervals specified in the owner’s manual.
1. Operate the engine until the water temperature reaches 60°C (140°F). Shut the engine off.
2. Use a container that can hold at least 14 liters (15 quarts) to hold the used oil. Remove the oil drain plug and
drain the used engine oil into the container.
3. Always check the condition of the used oil. This can give you an indication of engine problems that might exist.
Thin, black oil indicates fuel dilution.
Milky discoloration indicates coolant dilution.
4. Clean the area around the oil filter head. Remove the filter (Refer to 9 - ENGINE/LUBRICATION/OIL FILTER -
REMOVAL).
5. Install new oil filter (Refer to 9 - ENGINE/LUBRICATION/OIL FILTER - INSTA L L AT I O N ) .
6. Clean the drain plug and the sealing surface of the pan. Check the condition of the threads and sealing surface
on the oil pan and drain plug.
7. Install the drain plug. Tighten the plug to 50 Nꞏm (37 ft. lbs.) torque.
8. Use only High-Quality Multi-Viscosity lubricating oil in the Cummins Turbo Diesel engine. Choose the correct oil
for the operating conditions (Refer to LUBRICATION & MAINTENANCE/FLUID TYPES - DESCRIPTION).
9. Fill the engine with the correct grade of new oil (Refer to LUBRICATION & MAINTENANCE/FLUID CAPACITIES
- SPECIFICATIONS).
10. Start the engine and operate it at idle for several minutes. Check for leaks at the filter and drain plug.
11. Stop engine. Wait 15 minutes to allow the oil to drain back to the pan and check the level again.
USED ENGINE OIL DISPOSAL
Care should be exercised when disposing of used engine oil after it has beendrained from a vehicle’s engine.

3. Clean spark plug recesses with compressed air.
4. Remove the spark plugs.
5. Remove the oil fill cap.
6. Remove the air cleaner.
7. Calibrate the tester according to the manufacturer’s instructions. The shop air source for testing should maintain
483 kPa (70 psi) minimum, 1,379 kPa (200 psi) maximum, with 552 kPa (80 psi) recommended.
8. Perform the test procedures on each cylinder according to the tester manufacturer’s instructions. While testing,
listen for pressurized air escaping through the throttle body, tailpipe and oil filler cap opening. Check for bubbles
in the coolant pressure bottle.
All gauge pressure indications should be equal, with no more than 25 percent leakage per cylinder.
FOR EXAMPLE:At 552 kPa (80 psi) input pressure, a minimum of 414 kPa (60 psi) should be maintained in the
cylinder.
CYLINDER HEAD GASKET FAILURE DIAGNOSIS
A cylinder head gasket leak can be located between adjacent cylinders, between a cylinder and the adjacent water
jacket, or an external coolant leak may be present.
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.Cylinders adjacent to each other will both
have low compression.
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.

5. Identify the fluid in the cylinder(s) (i.e., coolant, fuel, oil or other).
6. Make sure all fluid has been removed from the cylinders. Inspect engine for damage (i.e., connecting rods, pis-
tons, valves, etc.)
7. Repair engine or components as necessary to prevent this problem from re-occurring.
CAUTION: Squirt approximately one teaspoon of oil into the cylinders, rotateenginetolubricatethecylin-
der walls to prevent damage on restart.
8. Install new spark plugs.
9. Drain engine oil and remove oil filter.
10. Fill engine with specified amount of approved oil and install new oil filter.
11. Connect negative battery cable.
12. Start engine and check for any leaks.
REMOVAL - ENGINE ASSEMBLY
1. Perform fuel pressure release procedure (Refer to
14 - FUEL SYSTEM/FUEL DELIVERY - STAN-
DARD PROCEDURE).
2. Disconnect negative battery cable.
3. Disconnect throttle body air inlet duct, remove air
cleaner cover (Refer to 9 - ENGINE/AIR INTAKE
SYSTEM/AIR CLEANER ELEMENT - REMOVAL).
4. Raise and support the vehicle.
5. Remove the lower engine shield.
6. Drain cooling system (Refer to 7 - COOLING/EN-
GINE - STANDARD PROCEDURE - DRAINING
COOLING SYSTEM).
7. Paint mark and remove the driveshaft (Refer to 3 -
DIFFERENTIAL & DRIVELINE/PROPELLER
SHAFT/PROPELLER SHAFT - REMOVAL).
8.Removethetransmission(Referto21-TRANS-
MISSION/TRANSAXLE/MANUAL - REMOVAL).
9. Remove the starter (Refer to 8 - ELECTRICAL/
STARTING/STARTER MOTOR - REMOVAL).
10. Disconnect the front exhaust pipe flange to
exhaust manifold fasteners (1 and 2).
11. Disconnect the hydraulic cooling fan lines and capture any spillage (Refer to 7 - COOLING/ENGINE/RADIATOR
FA N - R E M O VA L ) .
12. Drain engine oil and remove the oil filter.
13. Separate the air conditioning hose from the fan shroud.
14. Disconnect the lower radiator hose.
15. Disconnect the power steering line support bracket at the lower left ofthe radiator.
16. Loosen both engine mount through bolts.

COVER-TIMING CHAIN
REMOVAL
1. Disconnect negative battery cable.
2. Disconnect throttle body air inlet duct at the throttle
body, CCV hose, disconnect the IAT sensor and
remove air cleaner housing cover (Refer to 9 -
ENGINE/AIR INTAKE SYSTEM - REMOVAL).
3. Remove the oil indicator tube (1) fastener at the
right cylinder head cover.
4. Raise and support the vehicle.
5. Remove the lower engine shield.
6. Drain cooling system (Refer to 7 - COOLING/EN-
GINE - STANDARD PROCEDURE - DRAINING
COOLING SYSTEM).
7. Drain engine oil and remove oil filter (Refer to 9 -
ENGINE/LUBRICATION/OIL - STANDARD PRO-
CEDURE).
8. Drain power steering.
9. Disconnect the cooling fan return hose at radiator
fan.
10. Disconnect the radiator fan pressure hose to
power steering rack.
11. Disconnect the power steering hose to power steering pump.
12. Separate the A/C hose from the radiator fan module.
13. Remove the lower radiator hoses.
14. Remove the front frame cross member (Refer to 13 - FRAME & BUMPERS/FRAME/FRONT CROSSMEMBER
- REMOVAL).
15. Remove the flywheel inspection cover.
NOTE: Capture and properly dispose of any fuel spillage.
16. Disconnect oil cooler line at the timing cover using Special Tool 9005 (Refer to 9 - ENGINE/LUBRICATION/OIL
COOLER & LINES - STANDARD PROCEDURE).
17. Separate the oil cooler coolant hose from the timing cover.

OIL
STANDARD PROCEDURE
CHECKING ENGINE OIL LEVEL
The best time to check engine oil level is after the
vehicle has sat overnight. If the engine has been run-
ning, allow the engine to be shut off for at least 5 min-
utes before checking oil level.
Checking the oil while the vehicle is on level ground
will improve the accuracy of the oil level reading.
Remove the engine oil indicator. The indicator is cali-
brated for 1 quart within the SAFE zone.
ENGINE OIL AND FILTER CHANGE
WARNING: NEW OR USED ENGINE OIL CAN BE IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL. CONTAMINANTS IN USED ENGINE OIL, CAUSED BY INTER-
NAL COMBUSTION, CAN BE HAZARDOUS TO YOUR HEALTH. THOROUGHLY WASH EXPOSED SKIN WITH
SOAP AND WATER. DO NOT WASH SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR SOLVENTS,
HEALTH PROBLEMS CAN RESULT. DO NOT POLLUTE, DISPOSE OF USED ENGINE OIL PROPERLY. CON-
TACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER INYOUR
AREA.
Change engine oil and filter at mileage and time intervals described in LUBRICATION AND MAINTENANCE (Refer
to LUBRICATION & MAINTENANCE/MAINTENANCE SCHEDULES - DESCRIPTION).
ENGINE OIL AND FILTER CHANGE
1. Run engine until achieving normal operating temperature.
2. Position the vehicle on a level surface and turn engine off.
3. Open hood, remove oil fill cap.
4. Raise vehicle on hoist.
5. Remove underbody front shield
6. Place a suitable drain pan under oil pan drain plug.
7. Remove drain plug from oil pan and allow oil to drain into pan. Inspect drain plug threads for stretching or other
damage. Replace drain plug and gasket if damaged.
8. Install drain plug in crankcase.
9. Remove oil filter and replace with new.
10. Install under body shield.
11. Lower vehicle and fill crankcase with specified type (Refer to LUBRICATION & MAINTENANCE/FLUID TYPES
- DESCRIPTION) and amount of engine oil (Refer to LUBRICATION & MAINTENANCE - SPECIFICATIONS).