lock DODGE RAM SRT-10 2006 Service Repair Manual

11. The intake and exhaust valve stem seals should be pushed firmly and squarely over the valve guide using the
valve stem as guide. Push seal against top of guide. When installing the valve retainer locks, compress the
springonly enoughto install the locks.
CAUTION: Do not pinch seal between retainer and top of valve guide.
12. Follow the same procedure on the remaining 9 cylinders.Make sure piston is at TDC on the cylinder the
valve spring is being removed.
13. Remove spark plug adapter tool.
14. Install rocker arm and pedestal assemblies. Ensure push rods are seated properly under each rocker arm.
Tightenrockerarmboltsto35Nꞏm(26ft.lbs.).
15. Install cylinder head covers (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDERHEADCOVER(S)-INSTAL-
LATION).
16. Install spark plugs and connect secondary ignition wires.
17. Connect negative battery cable.
REMOVAL
NOTE: Before replacing parts, inspect all related
valvetrain components for damage to prevent
engine misfire.
1. With the cylinder head removed, compress valve
springs using a valve spring compressor (1).
2. Remove valve retaining locks.
3. Slowly release valve spring compressor.
4. Remove valve spring retainer and valve spring.
5. Before removing the valves,remove any burrs
from valve stem lock grooves to prevent dam-
age to the valve guides.Identify the valves to
ensure installation in original location.
6. Remove valve seal.
7. Repeat procedure for remaining valves.

INSTALLATION
NOTE: Before replacing parts, inspect all related
valvetrain components for damage to prevent
engine misfire.
NOTE: Black valve seals are intake. Brown valve
seals are exhaust.
1. Install valve seals (1).
2. Coat the valve stems with clean engine oil and
insert them in the cylinder head.
3. Install valve spring seats (6).
4. Install valve springs and valve retainers (2).
5. Compress valve springs with a valve spring com-
pressor. Install retaining locks and release tool.
6.If valves and/or seats have been reground,
measure valve tip height (A). Make sure mea-
surements are taken from cylinder head surface
to the top of valve stem.If valve tip height is
greater than 52.96 mm (2.085 in.), grind the valve
tip until within specifications.
7.If valves and/or seats have been reground,
measure installed height of springs (B). Make
sure measurements are taken from top of
spring seat to the bottom surface of valve
spring retainer.If height is greater than 44.45 mm (1.75 in.), install a 0.794 mm (.031 in.) spacer in head
counter-bore under the valve spring seat to bring spring height back to 43.69 - 44.45 mm (1.72 - 1.75 in.).

25. Remove A/C compressor mounting bolts. Reposi-
tion A/C compressor.Do notdisconnect A/C lines.
26. Disconnect the power steering line support
bracket at the radiator.
27. Lower the vehicle.
28. Remove the upper radiator hose and coolant
recovery container.
29. Remove the cooling fan module (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN -
REMOVAL).
30. Remove the upper idler pulley.
31. Remove power steering pump mounting bolts.
Reposition power steering pump aside.Do not
disconnect power steering lines.
32. Remove the generator (Refer to 8 - ELECTRI-
CAL/CHARGING/GENERATOR - REMOVAL).
33. Disconnect the heater hose at the timing cover.
34. Disconnect the ground wire at the thermostat
housing.
NOTE: Do Not remove the camshaft position sensor from the timing cover.
35. Disconnect the camshaft sensor wiring harness connector.
36. Disconnect engine coolant temperature (ECT) sensor connector.
37. Remove crankshaft pulley and damper (Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
38. Remove the timing cover.
INSTALLATION
CAUTION: Do not use a metal scraper to clean alu-
minum sealing surfaces, as damage to surfaces
may occur. Use only a plastic scraper and Mopar
Brake Parts Cleaner or the equivalent.
1. Be sure mating surfaces of chain case cover and
cylinder block are clean and free from burrs.
Crankshaft oil seal must be removed to insure cor-
rect oil pump engagement.
2. Install the timing chain cover gasket.
3. Position the oil pump inner rotor mating flats in the
same position as the crankshaft drive flats.
4. Install the timing chain cover onto crankshaft.
Ensure the oil pump is engaged on the crankshaft
correctly or severe damage may result (Refer to 9 -
ENGINE/LUBRICATION/OIL PUMP -
INSTALLATION).

5. Hand start bolts No.1 and No.2.
6. Loosely install A/C compressor mounting bracket.
7. Hand start remaining timing chain cover bolts.
8. Torque timing chain cover bolts in the sequence
showninto23Nꞏm(200in.lbs.).
9. Torque A/C compressor mounting bracket bolts to
23 Nꞏm (200 in. lbs.).
10. Install crankshaft oil seal (Refer to 9 - ENGINE/
ENGINE BLOCK/CRANKSHAFT OIL SEAL -
FRONT - INSTALLATION).
11. Raise vehicle on hoist.
12. Install oil pump pick up tube using anewo-ring.
Torque 1/4–20 bolt to 11 Nꞏm (95 in. lbs.). Torque
5/16–18 nuts to 23 Nꞏm (200 in. lbs.).
13. Support the engine with a jack stand.
14. Install oil pan and drain plug (Refer to 9 -
ENGINE/LUBRICATION/OIL PAN - INSTALLA-
TION).
15. Remove the jackstand.
16. Tighten the engine mount to frame nuts to 102
Nꞏm (75 ft.lbs.).
17. Connect the oil cooler coolant hose to the timing
cover.
18. Connect the oil cooler line (Refer to 9 - ENGINE/
LUBRICATION/OIL COOLER & LINES - STAN-
DARD PROCEDURE).
19. Install the lower radiator hose.
20. Install the flywheel inspection cover.
21. Install the front frame cross member (Refer to 13
- FRAME & BUMPERS/FRAME/FRONT CROSS-
MEMBER - INSTALLATION).
22. Lower vehicle.
23. Position the compressor and install A/C compressor mounting bolts. Torque bolts to 23 Nꞏm (200 in. lbs.).
24. Connect heater hose at timing cover.
25. Install crankshaft damper and pulley (Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - INSTAL-
LATION).
26. Install generator. Connect electrical connectors.
27. Install the idler pulley.
28. Connect the camshaft position sensor wiring harness connector.
29. Connect engine coolant temperature (ECT) sensor wiring harness connector.
30. Install power steering pump mounting bolts.
31. Install accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
32. Install the radiator fan assembly (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - INSTALLATION).

TIMING CHAIN ANDCAMSHAFT SPROCKET INSTALLATION
1. Rotate the crankshaft sprocket so the timing mark
is at the 12 O’clock position.
2. Place the timing chain around the camshaft
sprocket and place the timing mark to the 6 O’clock
position.
3. Place the timing chain around crankshaft sprocket
and install the camshaft sprocket into position.
4. Using straight edge, check alignment of timing
marks.
5. Install the camshaft sprocket bolts. Tighten the
bolts to 23 Nꞏm (200 in. lbs.).
6. Rotate crankshaft 2 revolutions. Timing marks
should line up. If timing marks do not line up,
remove cam sprocket and realign.
7. Measure camshaft end play. (Refer to 9 - ENGINE
- SPECIFICATIONS). If not within specifications,
install new thrust plate.
8. Install timing chain cover (Refer to 9 - ENGINE/
VALVE TIMING/TIMING CHAIN COVER -
INSTALLATION).

LUBRICATION
DESCRIPTION
The engine lubrication system is a full-flow filtration pressure feed type.
OPERATION
Engine oil stored in the oil pan is taken in and discharged by an internal geartypeoilpump,whichisdrivenbythe
crankshaft. A pressure relief valve is located in the timing chain case cover; it regulates oil pressure. The oil is
pumped through an oil filter and feeds a main oil gallery. Also, oil is routedtoanexternaloilcooler.Themainoil
gallery feeds oil under pressure to the main bearings, connecting rod bearings, and camshaft bearings. Passages in
the cylinder block feed oil to the hydraulic lifters. The oil then flows through hollow pushrods, which feed the rocker
arm pivots.
DIAGNOSIS AND TESTING
CHECKING ENGINE OIL PRESSURE
1. Remove oil pressure sensor (Refer to 9 - ENGINE/LUBRICATION/OIL PRESSURE SENSOR - REMOVAL).
2. Install oil pressure gauge.
3. Warm engine at high idle until thermostat opens.
CAUTION: If oil pressure is 0 at idle, Do Not Run engine at 3000 RPM.
4. Oil pressure should be 68.9 kPa (10 psi) at idle or 310 - 517 kPa (45 - 75 psi)at 3000 RPM.
5. If oil pressure is 0 at idle, shut off engine. Check for a clogged oil pick-up screen or a pressure relief valve stuck
open.
ENGINE OIL LEAK
Begin with a thorough visual inspection of the engine, particularly at thearea of the suspected leak. If an oil leak
source is not readily identifiable, thefollowingstepsshouldbefollowed:
1. Do not clean or degrease the engine at this time because some solvents maycause rubber to swell, temporarily
stopping the leak.
2. Add an oil soluble dye (use as recommended by manufacturer). Start the engine and let idle for approximately 15
minutes. Check the oil dipstick to make sure the dye is thoroughly mixed as indicated with a bright yellow color
under a black light.
3. Using a black light, inspect the entire engine for fluorescent dye, particularly at the suspected area of oil leak. If
the oil leak is found and identified, repair per service manual instructions.
4. If dye is not observed, drive the vehicle at various speeds for approximately 24 km (15 miles), and repeat inspec-
tion.If the oil leak source is not positively identified at this time, proceed with the air leak detection test
method.
Air Leak Detection Test Method
1. Remove the PCV valve from the IAFM. Cap or plug the PCV valve grommet.
2. Attach an air hose with pressure gauge and regulator to the dipstick tube.
CAUTION: Do not subject the engine assembly to more than 20.6 kPa (3 PSI) of test pressure.
3. Gradually apply air pressure from 6.89 - 17.23 kPa (1 - 2.5 psi) maximum while applying soapy water at the
suspected source. Adjust the regulator to the suitable test pressure thatprovide the best bubbles which will pin-
point the leak source. If the oil leak is detected and identified, repair per service manual procedures.
4. If the leakage occurs at the rear oil seal area, refer to the section, Inspection for Rear Seal Area Leak.
5. If no leaks are detected, turn off the air supply and remove the air hose and all plugs and caps. Install the PCV
valve.
6. Clean the oil off the suspect oil leak area using a suitable solvent. Drive the vehicle at various speeds approx-
imately 24 km (15 miles). Inspect the engine for signs of an oil leak by usinga black light.

INSPECTION FOR REAR SEAL AREA LEAKS
Since it is sometimes difficult to determine the source of an oil leak in therear seal area of the engine, a more
involved inspection is necessary. The following steps should be followedto help pinpoint the source of the leak.
If the leakage occurs at the crankshaft rear oil seal area:
1. Disconnect the battery.
2. Raise the vehicle.
3. Remove torque converter or clutch housing cover and inspect rear of block for evidence of oil. Use a black light
to check for the oil leak:
a. Circular spray pattern generally indicates seal leakage or crankshaftdamage.
b. Where leakage tends to run straight down, possible causes are a porous block, distributor seal, camshaft
bore cup plugs oil galley pipe plugs, oil filter runoff, and main bearing cap to cylinder block mating surfaces.
4. If no leaks are detected, pressurize the crankcase as outlined in the, Inspection (Engine oil Leaks in general)
CAUTION: Do not exceed 20.6 kPa (3 psi).
5. If the leak is not detected, very slowly turn the crankshaft and watch forleakage. If a leak is detected between
the crankshaft and seal while slowly turning the crankshaft, it is possible the crankshaft seal surface is damaged.
The seal area on the crankshaft could have minor nicks or scratches that canbe polished out with emery cloth.
CAUTION: Use extreme caution when crankshaft polishing is necessary to remove minor nicks and
scratches. The crankshaft seal flange is especially machined to complement the function of the rear oil seal.
6. For bubbles that remain steady with shaft rotation, no further inspection can be done until disassembled.

2. Apply an 1/8 in. bead of Mopar Engine RTV at the two joints between the cylinder block to timing chain case
cover and the two joints between the rear main seal retainer and engine block.
3. Position oil pan and gasket to engine block, seat the oil level indicatortube in the oil pan and hand start all
fasteners.
4. Tighten the transmission to oil pan bolts in finger
tight.
5. Torque 5/16-18 oil pan bolts to 23 Nꞏm (200 in.
lbs.). Torque 1/4-20 oil pan bolts to 11 Nꞏm (95 in
lbs.).
6. Torque transmission to oil pan bolts to 23 Nꞏm (200
in. lbs.).
7. Lower the engine.
8. Install and tighten engine mount through bolts to
102 Nꞏm (75 ft. lbs.).
9. Install flywheel inspection cover.

BLOCK-ENGINE
DESCRIPTION
The cylinder block is made of a sand-cast aluminum alloy. The cylinder block has interference-fit cast iron cylinder
liners. The cylinder liners are thermally installed during block manufacturing; they are not serviceable items.
Six iron main bearing caps use four bolts per cap; two vertical and two horizontal. A crankshaft oil scraper is
attached to the main bearing caps via extended main bearing cap bolts and nuts.
STANDARD PROCEDURE - CYLINDER BORE HONING
Before honing, stuff plenty of clean shop towels under
the bores and over the crankshaft to keep abrasive
materials from entering the crankshaft area.
1. Used carefully, the Cylinder Bore Sizing Hone
C-823, equipped with 220 grit stones, is the best
tool for this job. In addition to deglazing, it will
reduce taper and out-of-round, as well as removing
light scuffing, scoring and scratches. Usually, a few
strokes will clean up a bore and maintain the
required limits.
CAUTION: DO NOT use rigid type hones to remove
cylinder wall glaze.
2. Deglazing of the cylinder walls may be done if the
cylinder bore is straight and round. Use a cylinder
surfacing hone, Honing Tool C-3501, equipped with
280 grit stones (C-3501-3810). about 20-60
strokes, depending on the bore condition, will be
sufficient to provide a satisfactory surface. Using
honing oil C-3501-3880, or a light honing oil, avail-
able from major oil distributors.
CAUTION: DO NOT use engine or transmission oil, mineral spirits, or kerosene.
3. Honing should be done by moving the hone up and down fast enough to get a crosshatch pattern. The hone
marks should INTERSECT at 50° to 60° for proper seating of rings.
4. A controlled hone motor speed between 200 and 300 RPM is necessary to obtain the proper crosshatch angle.
The number of up and down strokes per minute can be regulated to get the desired 50° to 60° angle. Faster up
and down strokes increase the crosshatch angle.
5. After honing, it is necessary that the block be cleaned to remove all traces of abrasive. Use a brush to wash
parts with a solution of hot water and detergent. Dry parts thoroughly. Usea clean, white, lint-free cloth to check
that the bore is clean. Oil the bores after cleaning to prevent rusting.
CLEANING
CAUTION: Remove all gasket material from cylinder block using a plastic gasket scraper and MoparBrake
Parts Cleaner or the equivalent, this will prevent damage to the cylinder block.
1. When cleaning the cylinder block, remove the oil gallery plugs at the front and rear of the block.
2. Spray compressed air into all oil gallery passages to ensure they are clear of blockage.
3. Use a wooden or plastic scraper and MOPAR
Brake Parts Cleaner or the equivalent to remove the old gasket.
4. Clean the oil passages in the crankshaft with a brush.

HYDRAULIC TAPPETS
DESCRIPTION
The roller type design hydraulic tappets (3) are posi-
tioned in the cylinder block. Roller tappet alignment is
maintained by machined flats on tappet body being fit-
ted in pairs into ten aligning yokes (2).
REMOVAL
1.Removecylinderhead(s)(Referto9-ENGINE/
CYLINDER HEAD - REMOVAL).
NOTE: If tappets (3) are to be reused, identify tap-
pet location to ensure installation in original loca-
tion.
2. Remove tappet aligning yoke bolt (1).
3. Remove tappets (3) from bores.
CAUTION: Do not disassemble tappets.