power steering DODGE RAM SRT-10 2006 Service Owner's Manual

INSTALLATION
1. Clean timing chain cover and block surface.
NOTE: Always install a new gasket on timing cover.
2. Verify that the slide bushings (1) are installed in timing cover.
3. Install cover and new gasket. Tighten fasteners to 28 Nꞏm (250 in. lbs.).
NOTE: The large lifting stud is torqued to 55 Nꞏm (40 ft. lbs.).
4. Install the oil pan and pick up tube (Refer to 9 -
ENGINE/LUBRICATION/OIL PAN - INSTALLA-
TION).
5. Install the A/C compressor.
6. Install the generator.
7. Install power steering pump.
8. Install the dipstick support bolt.
9. Install the thermostat housing.
10. Install crankshaft damper (Refer to 9 - ENGINE/
ENGINE BLOCK/VIBRATION DAMPER - INSTAL-
LATION).
11. Install accessory drive belt tensioner assembly
and both idler pulleys.

CONDITION POSSIBLE CAUSES CORRECTION
3. Improperly operating vibration
damper3. Inspect/replace vibration damper.
4. Improperly operating electronically
controlled viscous fan drive.4. Inspect/replace fan drive.
5. Worn or damaged generator
bearing.5. Check/replace generator.
6. Flywheel housing misaligned. 6. Check/correct flywheel alignment.
7. Loose or broken power
component.7. Inspect the crankshaft and rods for
damage that causes an unbalance
condition. Repair/replace as required.
8. Worn or unbalanced driveline
components.8. Check/repair driveline components.
EXCESSIVE ENGINE
NOISES1. Drive belt squeal, insufficient
tension or abnormally high loading.1. Check the automatic tensioner and
inspect the drive belt. Make sure water
pump, tensioner pulley, fan hub, generator
and power steering pump turn freely.
2. Intake air or exhaust leaks. 2. Refer to Excessive Exhaust Smoke
(Refer to 9 - ENGINE - DIAGNOSIS AND
TESTING).
3. Excessive valve lash. 3. Adjust valves. Make sure the push rods
are not bent and rocker arms, adjusting
screws, crossheads, are not severely worn.
Replace bent or severely worn components.
4. Turbocharger noise. 4. Check turbocharger impeller and turbine
wheel for housing contact. Repair/replace
as required.
5. Gear train noise. 5. Visually inspect and measure gear
backlash. Replace gears as required.
6. Power function knock. 6. Check/replace rod and main bearings.
DIAGNOSIS AND TESTING -SMOKE DIAGNOSIS CHARTS
The following charts include possible causes and corrections forexcess or abnormalexhaust smoke. Small
amounts of exhaust smoke (at certain times) are to be considered normal fora diesel powered engine.
EXCESSIVE BLACK SMOKE
POSSIBLE CAUSE CORRECTION
Air filter dirty or plugged. Check Filter Minder
at air filter (Refer to 9 - ENGINE/
AIR INTAKE SYSTEM/AIR CLEANER ELEMENT -
REMOVAL).
Air intake system restricted. Check entire air intake system including all hoses and
tubes for restrictions, collapsed parts or damage.
Repair/replace as necessary.
Air Leak in Intake System. Check entire air intake system (Refer to 11 - EXHAUST
SYSTEM/TURBOCHARGER SYSTEM/CHARGE AIR
COOLER AND PLUMBING - DIAGNOSIS AND
TESTING) including all hoses and tubes for cracks,
loose clamps and/or holes in rubber ducts. Also check
intake manifold for loose mounting hardware.
Diagnostic Trouble Codes (DTC’s) active or multiple,
intermittent DTC’s.Refer to Powertrain Diagnostic Procedures Information.

34. Remove lower fan shroud bracket (3) from
engine.
35. Remove upper fan shroud brackets from engine.
36. Disconnect engine block heater connector.
37. Disconnect A/C compressor and pressure sensor
electrical connectors.
38. Remove the passenger battery ground cable from
the engine block. Remove the driver side battery
ground cable from the engine block.
39. Remove power steering pump from engine by
removing 3 bolts.
40. Disconnect the ECM power connector.
41. Disconnect the ECM ground wire from the hydro-
form screw.
42. Disconnect the fuel supply and return hoses.
43. Remove the cylinder head cover (1). (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) -
REMOVAL).
44. Disconnect the wire harnesses from the injectors (3).
45. Remove the cylinder head cover carrier gasket (2).

19. Connect fuel supply and return hoses.
20. Connect ECM ground to hydroform screw. Con-
nect ECM power connector.
21. Install the power steering pump.
22. Install the damper and speed indicator ring.
Torque to 40 Nꞏm (30 ft. lb) plus 60 degrees.
23. Install lower fan shroud bracket (3). Torque to 24
Nꞏm (18 ft. lb).
24. Install upper fan shroud brackets, but do not
tighten fasteners at this time.
25. Connect the engine block heater connection.
26. Connect the A/C compressor and pressure sensor
connectors
27. Install the charge air cooler (2). Install and tighten
the charge air cooler mounting bolts (1) to 2 Nꞏm
(17 in. lbs).
28. Connect the charge air cooler tubes (4). Torque all
clampsto8Nꞏm(72in.lbs).

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.

SEAL - CRANKSHAFT OIL - FRONT
REMOVAL
1. Disconnect both battery negative cables.
2. Raise vehicle on hoist.
3. Partially drain engine coolant into container suitable for re-use (Refer to 7 - COOLING - STANDARD PROCE-
DURE).
4. Lower vehicle.
5. Remove radiator upper hose.
6. Disconnect coolant recovery bottle hose from radiator filler neck.
7. Disconnect windshield washer pump supply hose and electrical connections and lift washer bottle off of fan
shroud.
8. Remove viscous fan/drive assembly. (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - REMOVAL).
9. Remove cooling fan shroud and fan assembly from the vehicle.
10. Remove the accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
11. Remove the cooling fan support/hub from the front of the engine.
12. Raisethevehicleonhoist.
13. Remove the crankshaft damper and speed indicator ring.
14. Remove power steering pump.
15. Remove accessory drive belt tensioner.
16. Remove the gear cover-to-housing bolts and gen-
tly pry the cover away from the housing, taking
care not to mar the gasket surfaces. Remove
crank seal dust shield with cover.
17. Support the cover on a flat work surface with
wooden blocks, and using a suitable punch (1)
and hammer, drive the old seal out of the cover
from the back side of the cover to the front side.

INSTALLATION
CAUTION: The seal lip and the sealing surface on
thecrankshaftmustbefreeofalloilresidue,to
prevent leaks. The crankshaft and seal surface
must be completely dry when the seal is installed.
1. Clean cover and housing gasket mating surfaces.
Use a suitable scraper and be careful not to dam-
age the gear housing surface. Remove any old
sealer from the oil seal bore. Thoroughly clean the
front seal area of the crankshaft. Do not sand this
surface. The seal lip and the sealing surface on the
crankshaft must be free from all oil residue to pre-
vent seal leaks.
2. Inspect the gear housing and cover for cracks and
replace if necessary. Carefully straighten any bends
or imperfections in the gear cover with a ball-peen
hammer on a flat surface. Inspect the crankshaft
front journal for any grooves or nicks that would
affect the integrity of the new seal.
3. Apply a bead of Mopar
Stud & Bearing Mount to
the outside diameter of the seal. Do not lubricate the inside diameter of thenewseal.
4. With the cover supported by wood blocks, install the seal into the rear ofthe cover using crankshaft seal installer
Special Tool 8281 and driver handle C-4171. Strike the driver handle untilthe installation tool bottoms out on the
inside of the cover.
CAUTION: Do not distort or damage seal.
5. Install the plastic seal pilot (provided with seal kit)
into the crankshaft seal.
6. Apply a bead of Mopar
Silicone Rubber Adhesive
Sealant or equivalent to the gear housing cover
sealing surface.
7. Install the cover to the gear housing, aligning the
seal pilot with the nose of the crankshaft.
NOTE: Failure to follow the cover installation pro-
cedure can result in misalignment of the crank-
shaft seal to the crankshaft, causing an oil leak.
8. Install the cover bolts and hand snug 2 capscrews
at the 3 o’clock and 9 o’clock position, to keep the
cover from moving when the first capscrew is
torqued. Torque to 24 Nꞏm (18 ft. lbs.) torque. Remove pilot tool.
9. Install dust shield over nose of crankshaft.
10. Install the crankshaft damper and speed indicator ring. Torque the bolts to 40 Nꞏm (30 ft. lbs.). Then rotate an
additional 60°. Use the engine barring tool to keep the engine from rotating during tightening operation.
11. Install the fan support/hub assembly and torque bolts to 32 Nꞏm (24 ft. lbs.).
12. Install power steering pump.
13. Install accessory drive belt tensioner. Torque bolt to 43 Nꞏm (32 ft.lbs.).
14. Install cooling fan (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - INSTALLATION).
15. Install the accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
16. Refill cooling system (Refer to 7 - COOLING - STANDARD PROCEDURE).
17. Connect battery negative cables.

PUMP - ENGINE OIL
REMOVAL
1. Disconnect the battery negative cables.
2. Remove fan/drive assembly (Refer to 7 - COOL-
ING/ENGINE/RADIATOR FAN - REMOVAL).
3. Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
4. Remove the fan support/hub assembly.
5. Remove crankshaft damper (Refer to 9 - ENGINE/
ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL) and speed indicator ring.
6. Remove power steering pump.
7. Remove accessory drive belt tensioner.
8. Remove the gear housing cover (Refer to 9 -
ENGINE/VALVE TIMING/GEAR HOUSING COVER
- REMOVAL).
9. Remove the four mounting bolts (2) and pull the oil pump (1) from the bore in the cylinder block.
CLEANING
Clean all parts in solvent and dry with compressed air. Clean the old sealerresidue from the back of the gear
housing cover and front of the gear housing.
INSPECTION
Disassemble and inspect the oil pump as follows:
1. Visually inspect the lube pump gears for chips,
cracks or excessive wear.
2. Remove the back plate (1).
3. Mark TOP on the gerotor planetary (3) using a felt
tip pen.
4. Remove the gerotor planetary (3) inspect for
excessive wear or damage. Inspect the pump
housing and gerotor drive (2) for damaged and
excessive wear.
5. Install the gerotor planetary in the original position.
6. Measure the tip clearance (1). Maximum clearance
is 0.1778 mm (0.007 inch). If the oil pump is out of
limits, replace the pump.

3. The back plate on the pump seats against the bot-
tom of the bore in the cylinder block. When the
pump is correctly installed, the flange on the pump
will not touch the cylinder block.
4. Measure the idler gear to pump drive gear back-
lash and the idler gear to crankshaft gear backlash.
The backlash should be 0.15- 0.25 mm
(0.006-0.010 inch). If the backlash is out of limits,
replace the oil pump.
5. If the adjoining gear moves when you measure the
backlash, the reading will be incorrect.
6. Apply a bead of Mopar
Silicone Rubber Adhesive Sealant or equivalent to the gear housing cover sealing sur-
face.
7. Install the gear housing cover (Refer to 9 - ENGINE/VALVE TIMING/GEAR HOUSING COVER - INSTALLA-
TION).
8. Install the vibration damper (Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION) and
speed indicator ring.
9. Install the fan support/hub assemblyRefer to (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - INSTALLA-
TION)
10. Install power steering pump.
11. Install accessory drive belt tensioner. Torque bolt to 43 Nꞏm (32 ft. lbs.).
12. Install the accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
13. Install the cooling fan (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - INSTALLATION).
14. Connect battery negative cables.
15. Start engine and check for oil leaks.

CASE - FRONT
REMOVAL
1. Disconnect the battery negative cables.
2. Raise vehicle on hoist.
3. Partially drain engine coolant into container suitable for re-use (Refer to 7 - COOLING - STANDARD PROCE-
DURE).
4. Lower vehicle.
5. Remove radiator upper hose.
6. Disconnect coolant recovery bottle hose from radiator filler neck.
7. Remove viscous fan/drive/shroud assembly (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - REMOVAL).
8. Remove the accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
9. Remove the cooling fan support/hub from the front of the engine.
10. Raisethevehicleonhoist.
11. Remove the crankshaft damper (Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - REMOVAL) and
speed indicator ring.
12. Remove the lower fan shroud bracket.
13. Remove the upper fan shroud bracket that is mounted to the gear housing.
14. Lower the vehicle.
15. Remove the power steering pump.
16. Remove the accessory drive belt tensioner.
17. Remove the gear cover-to-housing bolts and gently pry the cover away from the housing, taking care not to mar
the gasket surfaces.
18. Remove the fuel injection pump (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL INJECTION PUMP -
REMOVAL).
19. Disconnect the camshaft position sensor connector.
20. Disconnect and remove engine speed sensor.
21. Remove the camshaft (Refer to 9 - ENGINE/ENGINE BLOCK/CAMSHAFT & BEARINGS (IN BLOCK) -
REMOVAL).
22. Remove the six front oil pan fasteners.
23. Remove the gear housing fasteners.
NOTE: Use care when removing the gear housing, to avoid damage to the oil pangasket, as the gasket will
be reused if it is not damaged.
24. Slide a feeler gauge between the gear housing and oil pan gasket, to break the gasket seal.
25. Remove the gear housing and gasket.
26. Clean the gasket material from the cylinder block and gear housing.