belt DODGE RAM SRT-10 2006 Service Manual Online

SEAL - CRANKSHAFT OIL - FRONT
REMOVAL
1. Disconnect negative cable from battery.
2. Remove accessory drive belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
3. Remove A/C compressor mouning fasteners and
set aside.
4. Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
5. Remove upper radiator hose.
6. Disconnect electrical connector for fan mounted
inside radiator shroud.
7. Remove radiator shroud attaching fasteners.
NOTE: Transmission cooler line snaps into shroud
lower right hand corner.
8. Remove radiator cooling fan and shroud (Refer to
7 - COOLING/ENGINE/RADIATOR FAN -
REMOVAL).
9. Remove crankshaft damper bolt.
10. Remove damper using Special Tools 8513 Insert
and 1026 Three Jaw Puller (2).
11. Using Special Tool 8511 (1), remove crankshaft
front seal.

INSTALLATION
CAUTION: To prevent severe damage to the Crank-
shaft, Damper or Special Tool 8512, thoroughly
clean the damper bore and the crankshaft nose
before installing Damper.
1. Using Special Tool 8348 and 8512 (2,3), install
crankshaft front seal.
2. Install vibration damper (Refer to 9 - ENGINE/EN-
GINE BLOCK/VIBRATION DAMPER - INSTALLA-
TION).
3. Installradiatorcoolingfanandshroud(Referto7-
COOLING/ENGINE/RADIATOR FAN - INSTALLA-
TION).
4. Install upper radiator hose.
5. Install A/C compressor and tighten fasteners to 54
Nꞏm (40 ft. lbs.).
6. Install accessory drive belt refer (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
7. Refill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
8. Connect negative cable to battery.

REMOVAL
1. Disconnect negative cable from battery.
2. Remove the following components:
Oil pan and gasket/windage tray (Refer to 9 - ENGINE/LUBRICATION/OIL PAN -REMOVAL).
Cylinder head covers (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL) and
(Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL).
Timing chain cover (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL).
Cylinder head(s) (Refer to 9 - ENGINE/CYLINDER HEAD - REMOVAL) and (Refer to 9 - ENGINE/CYLINDER
HEAD - REMOVAL).
3. If necessary, remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cyl-
inder block.Be sure to keep tops of pistons covered during this operation.Pistons and connecting rods
must be removed from top of cylinder block. When removing piston and connecting rod assemblies from the
engine, rotate crankshaft so the each connecting rod is centered in cylinder bore.
CAUTION: DO NOT use a number stamp or a punch to mark connecting rods or caps,as damage to con-
necting rods could occur
NOTE: Connecting rods and bearing caps are not interchangeable and shouldbe marked before removing
to ensure correct reassembly.
4. Mark connecting rod and bearing cap positions
using a permanent ink marker or scribe tool.
CAUTION: Care must be taken not to damage the
fractured rod and cap joint face surfaces, as
engine damage may occur.
5. Remove connecting rod cap. Install Special Tool 8507 Connecting Rod Guides into the connecting rod being
removed. Remove piston from cylinder bore. Repeat this procedure for eachpiston being removed.
CAUTION: Care must be taken not to nick crankshaft journals, as engine damage may occur
6. Immediately after piston and connecting rod removal, install bearing cap on the mating connecting rod to prevent
damage to the fractured cap and rod surfaces.
7. Carefully remove piston rings from piston(s), starting from the top ring down.
CLEANING
CAUTION: DO NOT use a wire wheel or other abrasive cleaning devise to clean the pistons or connecting
rods. The pistons have a Moly coating, this coating must not be damaged.
1. Using a suitable cleaning solvent clean the pistons in warm water and towel dry.
2. Use a wood or plastic scraper to clean the ring land grooves.
CAUTION: DO NOT remove the piston pin from the piston and connecting rod assembly.

5. The pistons are marked on the piston pin bore sur-
face with an raised “F” indicating installation posi-
tion (1). This mark must be pointing toward the
front of engine on both cylinder banks. The con-
necting rod oil slinger slot faces the front of the
engine.
6. Wipe cylinder bore clean and lubricate with engine
oil.
7. Rotate crankshaft until connecting rod journal is on
the center of cylinder bore. Insert rod and piston
into cylinder bore and carefully position connecting
rod guides over crankshaft journal.
8. Tap piston down in cylinder bore using a hammer
handle. While at the same time, guide connecting
rodintopositiononrodjournal.
CAUTION: Connecting Rod Bolts are Torque to
Yield Bolts and Must Not Be Reused. Always
replace the Rod Bolts whenever they are loosened
or removed.
9. Lubricate rod bolts and bearing surfaces with
engine oil. Install connecting rod cap and bearing. Tighten bolts to 27 Nꞏm(20 ft. lbs.) plus 90°.
10. Install the following components:
Cylinder head(s). (Refer to 9 - ENGINE/CYLINDER HEAD - INSTALLATION).
Timing chain and cover. (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTAL-
LATION).
Cylinderheadcovers(Referto9-ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLA-
TION).
Oil pan and gasket/windage tray. (Refer to 9 - ENGINE/LUBRICATION/OIL PAN- INSTALLATION).
11. Fill crankcase with proper engine oil to correct level.
12. Connect negative cable to battery.

DAMPER - CRANKSHAFT
REMOVAL
1. Disconnect negative cable from battery.
2. Remove accessory drive belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
3. Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
4. Remove radiator upper hose.
5. Remove upper fan shroud.
6. Using Special Tools 6958 Spanner with Adapter
Pins 8346 (1), loosen fan and viscous assembly
from water pump.
7. Remove fan and viscous assembly.
8. Disconnect electrical connector for fan mounted
inside radiator shroud.
NOTE: Transmission cooler line snaps into shroud
lower right hand corner.
9. Remove crankshaft damper bolt.
10. Remove damper using Special Tools 8513 Insert
and 1026 Three Jaw Puller (2).

INSTALLATION
CAUTION: To prevent severe damage to the Crank-
shaft, Damper or Special Tool 8512–A, thoroughly
clean the damper bore and the crankshaft nose
before installing Damper.
1. Align crankshaft damper slot with key in crankshaft.
Slide damper onto crankshaft slightly.
CAUTION: Special Tool 8512–A, is assembled in a
specific sequence. Failure to assemble this tool in
this sequence can result in tool failure and severe
damage to either the tool or the crankshaft.
2. Assemble Special Tool 8512–A as follows, The nut
(2) is threaded onto the shaft first. Then the roller
bearing (1) is placed onto the threaded rod (3)
(The hardened bearing surface of the bearing (1)
MUSTface the nut (2). Then the hardened washer (5) slides onto the threaded rod.Once assembled coat the
threaded rod’s threads with Mopar
Nickel Anti-Seize or equivalent.
3. Using Special Tool 8512–A, press damper onto
crankshaft (1).
4. Install then tighten crankshaft damper bolt to 175
Nꞏm (130 ft. lbs.).
5. Install fan blade assembly (Refer to 7 - COOLING/
ENGINE/FAN DRIVE VISCOUS CLUTCH -
INSTALLATION).
6. Install radiator upper shroud and tighten fasteners
to 11 Nꞏm (95 in. lbs.).
7. Connect electrical connector for shroud fan.
8. Install radiator upper hose.
9. Install accessory drive belt (Refer to 7 - COOLING/
ACCESSORY DRIVE/DRIVE BELTS - INSTALLA-
TION).
10. Refill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
11. Connect negative cable to battery.

PUMP - ENGINE OIL
REMOVAL
1. Remove the oil pan and pick-up tube (Refer to 9 - ENGINE/LUBRICATION/OILPA N - R E M O VA L ) .
2. Remove the timing chain cover (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) -
REMOVAL).
3. Remove the timing chains and tensioners (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL).
4. Remove the four bolts, primary timing chain tensioner and the oil pump.
DISASSEMBLY
1. Remove oil pump cover screws and lift off cover plate.
2. Remove pump inner and outer rotors.
NOTE: Once the oil pressure relief valve, cup plug, and pin are removed, thepump assembly must be
replaced.
3. If it is necessary to remove the pressure relief valve, drive the roll pinfrom pump housing and remove cup plug,
spring and valve.
CLEANING
1. Wash all parts in a suitable solvent.
INSPECTION
CAUTION: Oil pump pressure relief valve and
spring should not be removed from the oil pump.
If these components are disassembled and or
removed from the pump the entire oil pump
assembly must be replaced.
1. Clean all parts thoroughly. Mating surface of the oil
pump housing should be smooth. If the pump cover
is scratched or grooved the oil pump assembly
should be replaced.
2. Lay a straight edge across the pump cover surface
(3). If a 0.025 mm (0.001 in.) feeler gauge (2) can
be inserted between the cover and the straight
edge the oil pump assembly should be replaced.
3. Measure the thickness of the outer rotor. If the
outer rotor thickness measures at 12.005 mm
(0.472 in.) or less the oil pump assembly must be
replaced.
4. Measure the diameter of the outer rotor. If the outer
rotor diameter measures at 85.925 mm (3.382 in.)
or less the oil pump assembly must be replaced.

8. Place a straight edge (1) across the body of the oil
pump (between the bolt holes), if a feeler gauge (2)
of .095 mm (0.0038 in.) or greater can be inserted
between the straightedge and the rotors, the pump
must be replaced.
NOTE: The 3.7L/4.7L Oil pump is released as an
assembly. There are no DaimlerChrysler part num-
bers for Sub-Assembly components. In the event
the oil pump is not functioning or out of specifica-
tion it must be replaced as an assembly.
ASSEMBLY
1. Wash all parts in a suitable solvent and inspect carefully for damage or wear.
2. Install inner and outer rotors
3. Install oil pump cover plate and install cover bolts and tighten them to 12Nꞏm(105in.lbs.).
4. Prime oil pump before installation by filling rotor cavity with engine oil.
5. If oil pressure is low and pump is within specifications, inspect for worn engine bearings or other causes for oil
pressure loss.
INSTALLATION
1. Position the oil pump onto the crankshaft and
install one oil pump retaining bolt.
2. Position the primary timing chain tensioner and
install three retaining bolts.
3. Tighten the oil pump and primary timing chain ten-
sioner retaining bolts to 28 Nꞏm (250 in. lbs.) in the
sequence shown.
4. Install the secondary timing chain tensioners and
timing chains (Refer to 9 - ENGINE/VALVE TIM-
ING/TIMING BELT/CHAIN AND SPROCKETS -
INSTALLATION).
5. Install the timing chain cover (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT / CHAIN COVER(S)
- INSTALLATION).
6. Install the pick-up tube and oil pan (Refer to 9 -
ENGINE/LUBRICATION/OIL PAN -
INSTALLATION).

MANIFOLD - INTAKE
DESCRIPTION
The intake manifold is made of a composite material and features long runners which maximizes low end torque.
The intake manifold uses single plane sealing which consist of eight individual press in place port gaskets to prevent
leaks. Eight studs and two bolts are used to fasten the intake to the head.
DIAGNOSIS AND TESTING - INTAKE MANIFOLD LEAKAGE
An intake manifold air leak is characterized by lower than normal manifoldvacuum. Also, one or more cylinders may
not be functioning.
WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO NOT STAND IN ADIRECT LINE
WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE PULLEYS, BELTS OR THE FAN. DO NOT WEAR
LOOSE CLOTHING.
1. Start the engine.
2. Spray a small stream of water at the suspected leak area.
3. If a change in RPM is observed the area of the suspected leak has been found.
4. Repair as required.
REMOVAL
1. Disconnect negative cable from battery.
2. Remove resonator assembly and air inlet hose.
3. Disconnect throttle and speed control cables.
4. Disconnect electrical connectors for the following components:
Manifold Absolute Pressure (MAP) Sensor
Intake Air Temperature (IAT) Sensor
Throttle Position (TPS) Sensor
Coolant Temperature (CTS) Sensor
Idle Air Control (IAC) Motor
5. Disconnect brake booster hose and positive crankcase ventilation (PCV)hose.
6. Disconnect generator electrical connections.
7. Disconnect air conditioning compressor electrical connections.
8. Disconnect left and right radio suppressor straps.
9. Disconnect and remove ignition coil towers (Refer to 8 - ELECTRICAL/IGNITION CONTROL/IGNITION COIL -
REMOVAL).
10. Remove top oil dipstick tube retaining bolt and ground strap.
11. Bleed fuel system (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY - STANDARD PROCEDURE).
12. Remove fuel rail (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL RAIL - REMOVAL).
13. Remove throttle body assembly and mounting bracket.
14. Drain cooling system below coolant temperature level (Refer to 7 - COOLING - STANDARD PROCEDURE).

MANIFOLD - EXHAUST
DESCRIPTION
The exhaust manifolds are log style with a patented flow enhancing design to maximize performance. The exhaust
manifolds are made of high silicon molybdenum cast iron. A perforated coregraphite exhaust manifold gasket is
used to improve sealing to the cylinder head. The exhaust manifolds are covered by a three layer laminated heat
shield for thermal protection and noise reduction. The heat shields are fastened with a torque prevailing nut that is
backed off slightly to allow for the thermal expansion of the exhaust manifold.
REMOVAL
RIGHT EXHAUST MANIFOLD
1. Disconnect negative cable for battery.
2. Remove air cleaner assembly, resonator assembly and air inlet hose.
3. Remove accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
4. Remove A/C compressor (Refer to 24 -HEATING & AIR CONDITIONING/PLUMBING/A/C COMPRESSOR -
REMOVAL).
5. Remove A/C accumulator support bracket fastener.
6. Drain coolant below heater hose level (Refer to 7 - COOLING - STANDARD PROCEDURE).
7. Remove heater hoses at engine.
8. Remove fasteners(4,5) attaching exhaust manifold heat shield.
9. Remove heat shield.