heating DODGE RAM SRT-10 2006 Service Owner's Manual

12. Install gear housing cover (Refer to 9 - ENGINE/VALVE TIMING/GEAR HOUSING COVER - INSTALLATION).
Install front crankshaft dust seal.
13. Install the crankshaft damper with the speed indicator ring (Refer to 9- ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - INSTALLATION).
14. Install the fan support/hub assembly Refer to (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - INSTALLA-
TION).
15. Install the power steering pump.
16. Install accessory drive belt tensioner. Torque bolt to 43 Nꞏm (32 ft. lbs.).
17. Install the accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
18. Install the charge air cooler (with a/c condenser and auxiliary transmission oil cooler, if equipped) and tighten
the mounting bolts to 2 Nꞏm (17 in. lbs.) torque.
19. Connect charge air cooler inlet and outlet pipes. Tighten clamps to 11 Nꞏm (95 in. lbs.) torque.
20. Install the radiator upper support panel.
21. Close radiator petcock and lower the radiator into the engine compartment. Tighten the mounting bolts to 11
Nꞏm (95 in. lbs.) torque.
22. Raise vehicle on hoist.
23. Connect radiator lower hose and install clamp.
24. Connect transmission auxiliary oil cooler lines (if equipped).
25. Lower vehicle.
26. Install the fandrive/shroud assembly. (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - INSTALLATION)
27. Install the coolant recovery and windshield washer fluid reservoirs to the fan shroud.
28. Connect the coolant recovery hose to the radiator filler neck.
29. Add engine coolant (Refer to 7 - COOLING - STANDARD PROCEDURE).
30. Charge A/C system with refrigerant (if A/C equipped) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING - STANDARD PROCEDURE).
31. Connect the battery negative cables.
32. Start engine and check for engine oil and coolant leaks.

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.

17. Separate the ground strap (1) from the floor
board, above the right exhaust flange.
18. Lower the vehicle.
19. Discharge air conditioning system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/RE-
FRIGERANT - STANDARD PROCEDURE).
20. Remove the upper radiator hose.
21. Disconnect windshield washer hose at the splice.
22. Remove radiator core support.
23. Disconnect the cooling fan harness connector
(Refer to 7 - COOLING/ENGINE/RADIATOR FAN
- REMOVAL).
24. Remove the radiator and radiator fan assembly
(Refer to 7 - COOLING/ENGINE/RADIATOR -
REMOVAL).
25. Remove the A/C condenser, cap and position the
hoses aside.
26. Disconnect the heater hoses at the top front cover
and at the lower coolant housing and position
aside.
27. Disconnect the oil cooler hoses from the engine
and position aside (Refer to 9 - ENGINE/LUBRI-
CATION/OIL COOLER & LINES - STANDARD
PROCEDURE).
28. Remove accessory drive belt (1).
29. Disconnect and remove generator.
30. Remove power steering pump mounting bolts and
set pump aside.

4. Install the exhaust manifold heat shield nuts (2)
and tighten to 6 Nꞏm (50 in. lbs.).
5. Connect the ground strap to the thermostat hous-
ing and route the electrical and purge harness
underneath the throttle body and attach the con-
nectors.
6. Connect the fuel vapor purge lines.
7. Properly route and connect the spark plug wires.
8. Connect the engine electrical harnesses.
9. Connect the brake booster vacuum hose, fuel line,
cruise control and accelerator cables.
10. Install the A/C lines at the A/C compressor (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING/A/C COMPRESSOR - REMOVAL).
11. Connect A/C clutch electrical connector (Refer to
24 - HEATING & AIR CONDITIONING/PLUMB-
ING/A/C COMPRESSOR - REMOVAL).
12. Install the power steering pump.
13. Install the generator.
14. Install the accessory drive belt.
15. Connect the heater hoses to the engine.
16. Install the radiator and cooling fan assembly.
17. Install the A/C condenser.
18. Connect the A/C lines to the condenser.
19. Connect the cooling fan electrical connector.
20. Connect the windshield washer hose at the splice.
21. Install the coolant recovery container.
22. Install the upper radiator hose.
23. Install the throttle body air inlet duct and the air
cleaner element cover.
24. Raise and support the vehicle.
25. Install transmission.
26. Install transmission bolts and tighten bolts to:
7/16 Transmission bolts and washers (2) - 68
Nꞏm (50 ft. lbs.)
Transmission to top of engine - 41 Nꞏm (30 ft.
lbs.)
Transmission to oil pan (3) - 30 Nꞏm (22 ft. lbs.)
27. Install drive shaft.

30. Connect oil cooler lines (4) and connect the oil
pressure sensor (1) and oil temperature sensor
(5).
31. Install the power steering line support bracket at
the radiator.
32. Install lower radiator hose.
33. Connect the cooling fan hydraulic lines (Refer to 7
- COOLING/ENGINE/RADIATOR FAN - INSTAL-
LATION).
34. Connect the A/C line to the fan shroud.
35. Install under body shield.
36. Lower vehicle.
37. Fill engine crankcase with the proper oil to the
correct level (Refer to LUBRICATION & MAINTE-
NANCE/FLUID TYPES - SPECIFICATIONS).
38. Evacuate and recharge the air conditioning (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING - STANDARD PROCEDURE).
39. Fill the cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
40. Fill power steering to proper leveland purge the system (Refer to 19 - STEERING/PUMP - STANDARD PRO-
CEDURE).
41. Connect the negative battery cable.
42. Start the engine and run until operating temperature is obtained.
43. Turn engine off and inspect for leaks.
44. Recheck all fluid levels, fill as required.
SPECIFICATIONS
ENGINE
GENERAL SPECIFICATIONS
DESCRIPTION SPECIFICATION
Ty pe 9 0° V-1 0
Number of Cylinders 10
Firing Order 1-10-9-4-3-6-5-8-7-2
Compression Ratio 9.6:1
Brake Horsepower 501@5600 RPM
Torque 525 ft. lbs. @4100 RPM
Crankshaft Forged Steel
Cylinder Block Aluminum Alloy with Interference Fit Cast Iron Liners
Connecting Rods Cracked Cap Powdered Metal
Pistons Cast Aluminum Alloy
Metric Standard
Displacement 8.3L 505 cu. in.
Bore 102.4 mm 4.03 in.
Stroke 100.6 mm 3.96 in.
Compression Pressure 1069-1172 kPa 155-170 psi
Engine Weight (Approx.) 284 Kilograms 625 Lbs.

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).

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.

DIAGNOSIS AND TESTING
CHARGE AIR COOLER SYSTEM - LEAKS
Low turbocharger boost pressure and low engine per-
formance can be caused by leaks in the charge air
cooler or plumbing. Fuel staining on the exhaust man-
ifold can also be an indication that there are leaks in
the air system. The followingprocedure outlines how
to check for leaks in the charge air cooler system.
This procedure can also be used to check for leaks in
the wastegate signal line or the wastegate canister.
1. Loosen clamp and remove air inlet hose from tur-
bocharger.
2. Insert Special Tool 9022 Adapter into the turbo-
charger inlet. Tighten tool clamp to 8 Nꞏm (72 in.
lbs.).
CAUTION: Do not apply more than 138 kPa (20
psi) air pressure to the charge air cooler system,
severe damage to the charge air cooler system
may occur.
3. Connect a regulated air supply to air fitting on Tool
9022 Adapter. Set air pressure to a Maximum of
138 kPa (20 psi).
4. Using soapy water check the rubber sleeves, charge air cooler and intakemanifold for leaks.
5. Using soapy water check for leaks at the wastegate signal line, wastegate canister and wastegate command
valve.
REMOVAL
WARNING: IF THE ENGINE WAS JUST TURNED
OFF, THE AIR INTAKE SYSTEM TUBES MAY BE
HOT.
1. Disconnect the battery negative cables.
2. Discharge the A/C system (Refer to 24 - HEATING
& AIR CONDITIONING/PLUMBING - STANDARD
PROCEDURE) and remove the A/C condenser
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/A/C CONDENSER - REMOVAL) (if A/C
equipped).
3. Remove the transmission auxiliary cooler (Refer to
7 - COOLING/TRANSMISSION/TRANS COOLER -
REMOVAL).
4. Remove intake air tubing from the charge air
cooler.
5. Remove the charge air cooler bolts. Pivot the
charge air cooler forward and up to remove.

2. Install the air intake system tubes to the charge air
cooler. With the clamps in position, tighten the
clamps to 11 Nꞏm (95 in. lbs.) torque.
3. Install the transmission auxiliary cooler (if
equipped) (Refer to 7 - COOLING/TRANSMIS-
SION/TRANS COOLER - INSTALLATION).
4. Install the A/C condenser (if A/C equipped) (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING/A/C CONDENSER - INSTALLATION).
Recharge A/C system (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - STANDARD
PROCEDURE).
5. Connect the battery negative cables.
6. Start engine and check for boost system leaks.

2. Disconnect and isolate the battery negative cable.
3. Remove the front wheelhouse splash shield (Refer
to 23 - BODY/EXTERIOR/FRONT WHEELHOUSE
SPLASH SHIELD - REMOVAL).
4. Remove the fender (Refer to 23 - BODY/EXTERI-
OR/FRONT FENDER - REMOVAL).
5. Remove the A/C condenser, if required (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING/A/C
CONDENSER - REMOVAL).
6. Remove the A/C lines, if required. Refer to the
Heating and Air Conditioning section of the manual
for recommended procedures.
7. Remove the radiator assembly (4) (Refer to 7 -
COOLING/ENGINE/RADIATOR - REMOVAL).