ECU DODGE RAM SRT-10 2006 Service Service Manual

able in three ounce tubes and has a shelf life of one year. After one year thismaterial will not properly cure. Always
inspect the package for the expiration date before use.
MOPAR
GASKET MAKER
Mopar
Gasket Maker is an anaerobic type gasket material. The material cures in the absence of air when
squeezed between two metallic surfaces. It will not cure if left in the uncovered tube. The anaerobic material is for
use between two machined surfaces. Do not use on flexible metal flanges.
MOPAR
GASKET SEALANT
Mopar
Gasket Sealant is a slow drying, permanently soft sealer. This material isrecommended for sealing
threaded fittings and gaskets against leakage of oil and coolant. Can be used on threaded and machined parts
under all temperatures. This material is used on engines with multi-layersteel (MLS) cylinder head gaskets. This
material also will prevent corrosion. Mopar
Gasket Sealant is available in a 13 oz. aerosol can or 4oz./16 oz. can
w/applicator.
FORM-IN-PLACE GASKET AND SEALER APPLICATION
Assembling parts using a form-in-place gasket requires care but it’s easier than using precut gaskets.
Mopar
Gasket Maker material should be applied sparingly 1 mm (0.040 in.) diameter or less of sealant to one
gasket surface. Be certain the material surrounds each mounting hole. Excess material can easily be wiped off.
Components should be torqued in place within 15 minutes. The use of a locating dowel is recommended during
assembly to prevent smearing material off the location.
Mopar
Engine RTV GEN II or ATF RTV gasket material should be applied in a continuous bead approximately 3
mm (0.120 in.) in diameter. All mounting holes must be circled. For corner sealing, a 3.17 or 6.35 mm (1/8 or 1/4 in.)
drop is placed in the center of the gasket contact area. Uncured sealant maybe removed with a shop towel. Com-
ponents should be torqued in place while the sealant is still wet to the touch (within 10 minutes). The usage of a
locating dowel is recommended during assembly to prevent smearing material off the location.
Mopar
Gasket Sealant in an aerosol can should be applied using a thin, even coat sprayed completely over both
surfaces to be joined, and both sides of a gasket. Then proceed with assembly. Material in a can w/applicator can
be brushed on evenly over the sealing surfaces. Material in an aerosol can shouldbeusedonengineswithmulti-
layer steel gaskets.
REMOVAL
NOTE:Thisprocedureappliestoboththe4X2and4X4vehicles,stepsthatapply to the 4X4 vehicle only,
are identified.
1. Release fuel rail pressure (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY - STANDARD PROCEDURE) then
disconnect the fuel supply quick connect fitting at the fuel rail (Refer to14 - FUEL SYSTEM/FUEL DELIVERY/
QUICK CONNECT FITTING - STANDARD PROCEDURE).
2. Disconnect the battery negative and positive cables.
3. Raise vehicle on hoist.
4. Remove exhaust crossover pipe from exhaust manifolds.
5.4X4 vehiclesDisconnect axle vent tube from left side engine mount.
6. Remove the through bolt retaining nut and bolt from both the left and right side engine mounts.
7.4X4 vehiclesRemove locknut from left and right side engine mount brackets.
8. Disconnect two ground straps from the lower left hand side and one groundstrap from the lower right hand side
of the engine.

30. Disconnect engine harness at the following points
:
Intake air temperature (IAT) sensor (4)
Fuel Injectors
Throttle Position (TPS) Switch (2)
Idle Air Control (IAC) Motor (3)
Engine Oil Pressure Switch
Engine Coolant Temperature (ECT) Sensor
Manifold absolute pressure (MAP) Sensor
Camshaft Position (CMP) Sensor
Coil Over Plugs
31. Disconnect the vacuum lines at the throttle body
and intake manifold.
32. Remove power steering pump and position out of
the way.
33. Install Special Tools 8400 Lifting Studs, into the
cylinder heads.
34. Install Engine Lifting Fixture Special Tool 8347 (3)
following these steps.
Holding the lifting fixture at a slight angle, slide
the large bore in the front plate over the hex por-
tion of the lifting stud.
Position the two remaining fixture arms onto the
two Special Tools 8400 Lifting Studs, in the cyl-
inder heads.
Pull foward and upward on the lifting fixture so
that the lifting stud rest in the slotted area below
the large bore.
Secure the lifting fixture to the three studs using
three 7/16 – 14 N/C locknuts.
Make sure the lifting loop in the lifting fixture is in
the last hole (closest to the throttle body) to min-
imize the angle of engine during removal.

CAUTION: Do not hold or pry on the camshaft target wheel (Located on the right side camshaft sprocket)
for any reason, Severe damage will occur to the target wheel resulting in a vehicle no start condition.
4. Loosen butDO NOTremove the camshaft sprocket retaining bolt. Leave the bolt snug against the sprocket.
NOTE: The timing chain tensioners must be secured prior to removing the camshaft sprockets. Failure to
secure tensioners will allow the tensioners to extend, requiring timing chain cover removal in order to reset
tensioners.
CAUTION: Do not force wedge past the narrowest point between the chain strands. Damage to the tension-
ers may occur.
5. Position Special Tool 8350 (4) timing chain wedge between the timing chain strands, tap the tool to securely
wedge the timing chain against the tensioner arm and guide.
NOTE: When gripping the camshaft, place the pli-
ers on the tube portion of the camshaft only. Do
not grip the lobes or the sprocket areas.
6. Hold the camshaft (3) with adjustable pliers (2)
while removing the camshaft sprocket bolt and
sprocket (1).
7. Using the pliers, gently allow the camshaft to rotate
15° clockwise until the camshaft is in the neutral
position (no valve load).

CAUTION: Do not hold or pry on the camshaft tar-
get wheel for any reason, Severe damage will
occur to the target wheel. A damaged target wheel
could cause a vehicle no start condition.
4. Loosen butDO NOTremove the camshaft sprocket
retaining bolt (2). Leave bolt snug against sprocket
(3).
NOTE: The timing chain tensioners must be secured prior to removing the camshaft sprockets. Failure to
secure tensioners will allow the tensioners to extend, requiring timing chain cover removal in order to reset
tensioners.
CAUTION: Do not force wedge (3) past the narrowest point between the chain strands. Damage to the ten-
sioners may occur.
5. Position Special Tool 8350 timing chain wedge (3) between the timing chain strands. Tap the tool to securely
wedge the timing chain against the tensioner arm and guide.

8. Remove radiator (1) (Refer to 7 - COOLING/EN-
GINE/RADIATOR - REMOVAL).
9. Remove the upper crossmember and top core
support.
NOTE: It is not necessary to drain A/C system for
engine removal.
10. Remove the A/C compressor (2) with the lines
attached. Secure compressor out of the way.

MoparEngine RTV GEN II is used to seal components exposed to engine oil. This material is a specially designed
black silicone rubber RTV that retains adhesion and sealing properties when exposed to engine oil. Moisture in the
air causes the material to cure. This material is available in three ounce tubes and has a shelf life of one year. After
one year this material will not properly cure. Always inspect the package for the expiration date before use.
MOPAR
AT F R T V
Mopar
ATF RTV is a specifically designed black silicone rubber RTV that retains adhesion and sealing properties
to seal components exposed to automatic transmission fluid, engine coolants, and moisture. This material is avail-
able in three ounce tubes and has a shelf life of one year. After one year thismaterial will not properly cure. Always
inspect the package for the expiration date before use.
MOPAR
GASKET MAKER
Mopar
Gasket Maker is an anaerobic type gasket material. The material cures in the absence of air when
squeezed between two metallic surfaces. It will not cure if left in the uncovered tube. The anaerobic material is for
use between two machined surfaces. Do not use on flexible metal flanges.
MOPAR
GASKET SEALANT
Mopar
Gasket Sealant is a slow drying, permanently soft sealer. This material isrecommended for sealing
threaded fittings and gaskets against leakage of oil and coolant. Can be used on threaded and machined parts
under all temperatures. This material is used on engines with multi-layersteel (MLS) cylinder head gaskets. This
material also will prevent corrosion. Mopar
Gasket Sealant is available in a 13 oz. aerosol can or 4oz./16 oz. can
w/applicator.
FORM-IN-PLACE GASKET AND SEALER APPLICATION
Assembling parts using a form-in-place gasket requires care but it’s easier than using precut gaskets.
Mopar
Gasket Maker material should be applied sparingly 1 mm (0.040 in.) diameter or less of sealant to one
gasket surface. Be certain the material surrounds each mounting hole. Excess material can easily be wiped off.
Components should be torqued in place within 15 minutes. The use of a locating dowel is recommended during
assembly to prevent smearing material off the location.
Mopar
Engine RTV GEN II or ATF RTV gasket material should be applied in a continuous bead approximately 3
mm (0.120 in.) in diameter. All mounting holes must be circled. For corner sealing, a 3.17 or 6.35 mm (1/8 or 1/4 in.)
drop is placed in the center of the gasket contact area. Uncured sealant maybe removed with a shop towel. Com-
ponents should be torqued in place while the sealant is still wet to the touch (within 10 minutes). The usage of a
locating dowel is recommended during assembly to prevent smearing material off the location.
Mopar
Gasket Sealant in an aerosol can should be applied using a thin, even coat sprayed completely over both
surfaces to be joined, and both sides of a gasket. Then proceed with assembly. Material in a can w/applicator can
be brushed on evenly over the sealing surfaces. Material in an aerosol can shouldbeusedonengineswithmulti-
layer steel gaskets.
STANDARD PROCEDURE - REPAIR DAMAGED OR WORN THREADS
CAUTION: Be sure that the tapped holes maintain the original center line.
Damaged or worn threads can be repaired. Essentially, this repair consistsof:
Drilling out worn or damaged threads.
Tapping the hole with a special Heli-Coil Tap, or equivalent.
Installing an insert into the tapped hole to bring the hole back to its original thread size.
STANDARD PROCEDURE—HYDROSTATIC LOCK
CAUTION: DO NOT use the starter motor to rotate the crankshaft. Severe damage could occur.
When an engine is suspected of hydrostatic lock (regardless of what causedthe problem), follow the steps below.
1. Disconnect the negative cable(s) from the battery.
2. Inspect air cleaner, induction system, and intake manifold to ensure system is dry and clear of foreign material.

d. Install fuel line brace bolts-to-intake manifold finger tight for fuellines#2thru#5.
e. Install fuel line brace nut to rear lift bracket stud, finger tight, for fuel line #6.
f. Hand tighten fuel pump to fuel rail line.
g. Torque fuel line nuts at cylinder head to 30 Nꞏm ( 22 ft. lbs.).
h. Torque fuel line nuts at fuel rail to 30 Nꞏm (22 ft. lbs.)
i. Usingabackupwrench,torquefuelpumptofuelraillineto37Nꞏm(27ft.lbs.). At injection pump.
j. Torque fuel pump to fuel rail line to 37 Nꞏm (27 ft. lbs.) at fuel rail.
k. Torque fuel drain banjo bolt at pressure limiting valve and front of fuelfilter housing to 24 Nꞏm (18 ft. lbs.).
l. Torque fuel line brace bolts to 24 Nꞏm (18 ft. lbs.).
m. Torque fuel line brace nut to 24 Nꞏm (18 ft. lbs.).
n. Torque rail bolts to 24 Nꞏm (18 ft. lbs.).
o. Connect fuel pressure sensor.
p. Torque fuel filter mounting bolts to 24 Nꞏm (18 ft. lbs.).
19. Reposition number 6 fuel line shield and torque to 43 Nꞏm (32 ft. lbs.).
20. Install the fuel filter to injection pump low pressure line. Inspect and replace sealing washers if necessary.
Torque banjo bolts to 24 Nꞏm (18 ft. lbs.).
21. Connect fuel return line at back of cylinder head hand tight.
22. Connect fuel return line at filter housing hand tight.
23. Torque banjo connections at cylinder head and fuel filter housing to 24Nꞏm (18 ft. lbs.)
24. Install bracket to rear of filter housing. Torque to 24 Nꞏm (18 ft. lbs.).
25. Using new gaskets, install the intake grid heater and air inlet housing. Torque bolts to 24 Nꞏm (18 ft. lbs.).
26. Install wire harness P-clip and push on clip to air inlet housing.
27. Connect engine oil level indicator tube at fuel filter housing and at air inlet housing.
28. Install the charge air cooler-to-air inlet housing duct assembly. Torque all clamps to 11 Nꞏm (100 in. lbs.).
29. Connect intake grid heater wires.
30. Secure engine harness to front of cylinder head with bolt at four locations.
31. Connect engine coolant temperature sensor connector.
32. Connect radiator upper hose to thermostat housing.
33. Rotate generator into position. Install upper bolt and torque upper and lower bolts.
34. Install wire harness push-on clip below bracket.
35. Install wire harness P-clip to top of bracket.
36. Install fan support and torque to 32 Nꞏm (24 ft. lbs.).
37. Install cooling fan/drive refer to (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - INSTALLATION).
38. Install accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
39. Install exhaust manifold/turbocharger assembly, using new gaskets.Start all bolts/spacers by hand. Starting
from the center bolts out, Torque bolts to 43 Nꞏm (32 ft. lbs.), then retorque from the center out again.
40. Install exhaust manifold heat shield to exhaust manifold studs. Install retaining nuts.Torque to 24 Nꞏm (18 ft.
lbs.).
41. Install exhaust bolt retention straps across cylinders 5 & 6.
42. Using a new gasket, connect the turbocharger oil drain tube. Torque to 24Nꞏm(18ft.lbs.).
43. Perform the turbocharger pre-lube procedure. (Refer to 11 - EXHAUST SYSTEM/TURBOCHARGER SYSTEM/
TURBOCHARGER - INSTALLATION)
44. Connect the turbocharger oil supply line. Torque to 24 Nꞏm (18 ft. lbs.).
45. Install air cleaner housing and duct.
46. Connect air inlet temperature/pressure sensor.
47. Raise vehicle on hoist.

6. With the tappet in place, rotate the trough one half
turn so the open side is down (toward crankshaft).
7. Remove the tappet installation tool from the tappet.
8. Re-install a dowel rod and secure the rod with a
rubber band.
9. Rotate the trough one half turn and repeat the pro-
cedure for the remaining tappets.
10. Install the camshaft (Refer to 9 - ENGINE/EN-
GINE BLOCK/CAMSHAFT & BEARINGS (IN
BLOCK) - INSTALLATION).

37. Install Special Tool 9363 - Engine Lifting Brackets
(1) and to the exhaust manifold heat shield studs
where indicated.
38. Insert engine lifting bar (1) through the access
holes in the engine lifting brackets (2) and secure
with the bar retaining pins (3).

ASSEMBLY
1. Align oil cooler line (3) with quick connect fitting (1)
while pushing straight into the fitting.
2. Push in on oil cooler line (3) until a “click” is heard
or felt.
3. Slide dust cap (4) down the oil cooler line (3) and
snap it over the quick connect fitting (1) until it is
fully seated and rotates freely. Dust cap (4) will
only snap over quick connect fitting (1) when the
cooler line (3) is properly installed.
NOTE: If dust cap will not snap into place, repeat
assembly step #2.
REMOVAL
1. Disconnect oil cooler coolant hoses (3).
2. Disconnect throttle body air inlet hose, remove air
cleaner housing assembly (Refer to 9 - ENGINE/
AIR INTAKE SYSTEM/AIR CLEANER HOUSING -
REMOVAL).
3. Drain cooling system (Refer to 7 - COOLING/EN-
GINE - STANDARD PROCEDURE).
4. Using Special Tool 9005, disconnect oil supply (1)
and return lines (2) at oil cooler (Refer to 9 -
ENGINE/LUBRICATION/OIL COOLER & LINES -
STANDARD PROCEDURE).
5. Remove fasteners securing oil cooler to inner
fender and remove oil cooler.