2006 DODGE RAM SRT-10 air conditioning

CAMSHAFT & BEARINGS (IN BLOCK)
REMOVAL
CAMSHAFT BEARINGS
NOTE: Measure the diameter of each bore. If the camshaft bore for the cam bushing is worn beyond the
limit, install a new service bushing. Inspect the rest of the camshaft bores for damage or excessive wear.If
the bores without a bushing are worn beyond the limit, the engine must be removed for machining and
installation of service bushings. If badly worn, replace the cylinder block.
1. Remove the camshaft (Refer to 9 - ENGINE/ENGINE BLOCK/CAMSHAFT & BEARINGS (IN BLOCK) -
REMOVAL).
2. Remove the bushing from the No.1 bore.
3. Mark the cylinder block so you can align the oil hole in the cylinder blockwith the oil hole in the bushing.
CAMSHAFT
1. Disconnect both battery negative cables.
2. Recover A/C refrigerant (if A/C equipped) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STAN-
DARD PROCEDURE).
3. Raise vehicle on hoist.
4. Drain engine coolant into container suitable for re-use (Refer to 7 - COOLING - STANDARD PROCEDURE).
5. Lower vehicle.
6. Remove radiator upper hose.
7. Remove viscous fan/drive/shroud assembly (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - REMOVAL).
8. Disconnect the coolant recovery bottle hose from the radiator filler neck.
9. Disconnect lower radiator hose from radiator outlet.
10.Automatic Transmission models:Disconnect transmission oil cooler lines from front of radiator using Special
Tool 6931 (unless equipped with finger-release disconnect).
11. Remove radiator mounting screws and lift radiator out of engine compartment.
12. Remove upper radiator support panel.
13. If A/C equipped, disconnect A/C condenser refrigerant lines.
14. Disconnect charge air cooler piping from the cooler inlet and outlet.
15. Remove the two charge air cooler mounting bolts.
16. Remove charge air cooler (and A/C condenser if equipped) from vehicle.
17. Remove accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
18. Remove accessory drive belt tensioner.
19. Remove the fan support/hub assembly.
20. Remove crankshaft damper and speed indicator ring (Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL).
21. Remove the gear cover-to-housing bolts and gently pry the cover away from the housing, taking care not to mar
the sealing surfaces. Remove dust seal with cover.
22. Using Special Tool 7471–B Crankshaft Barring Tool, rotate the crankshaft to align the timing marks on the
crankshaft and the camshaft gears.
23. Remove the cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) -
REMOVAL).

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.

5. Identify the fluid in the cylinder(s) (i.e., coolant, fuel, oil or other).
6. Make sure all fluid has been removed from the cylinders. Inspect engine for damage (i.e., connecting rods, pis-
tons, valves, etc.)
7. Repair engine or components as necessary to prevent this problem from re-occurring.
CAUTION: Squirt approximately one teaspoon of oil into the cylinders, rotateenginetolubricatethecylin-
der walls to prevent damage on restart.
8. Install new spark plugs.
9. Drain engine oil and remove oil filter.
10. Fill engine with specified amount of approved oil and install new oil filter.
11. Connect negative battery cable.
12. Start engine and check for any leaks.
REMOVAL - ENGINE ASSEMBLY
1. Perform fuel pressure release procedure (Refer to
14 - FUEL SYSTEM/FUEL DELIVERY - STAN-
DARD PROCEDURE).
2. Disconnect negative battery cable.
3. Disconnect throttle body air inlet duct, remove air
cleaner cover (Refer to 9 - ENGINE/AIR INTAKE
SYSTEM/AIR CLEANER ELEMENT - REMOVAL).
4. Raise and support the vehicle.
5. Remove the lower engine shield.
6. Drain cooling system (Refer to 7 - COOLING/EN-
GINE - STANDARD PROCEDURE - DRAINING
COOLING SYSTEM).
7. Paint mark and remove the driveshaft (Refer to 3 -
DIFFERENTIAL & DRIVELINE/PROPELLER
SHAFT/PROPELLER SHAFT - REMOVAL).
8.Removethetransmission(Referto21-TRANS-
MISSION/TRANSAXLE/MANUAL - REMOVAL).
9. Remove the starter (Refer to 8 - ELECTRICAL/
STARTING/STARTER MOTOR - REMOVAL).
10. Disconnect the front exhaust pipe flange to
exhaust manifold fasteners (1 and 2).
11. Disconnect the hydraulic cooling fan lines and capture any spillage (Refer to 7 - COOLING/ENGINE/RADIATOR
FA N - R E M O VA L ) .
12. Drain engine oil and remove the oil filter.
13. Separate the air conditioning hose from the fan shroud.
14. Disconnect the lower radiator hose.
15. Disconnect the power steering line support bracket at the lower left ofthe radiator.
16. Loosen both engine mount through bolts.

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.

SPRINGS/SEALS-VALVE
DIAGNOSIS AND TESTING
VA LV E S P R I N G T E S T I N G
The valve springs should be tested whenever
removed for inspection, reconditioning, or replace-
ment.
1. Obtain specifications for spring tension at specified
spring length (Refer to 9 - ENGINE - SPECIFICA-
TIONS).
2. Turn table of Special Tool C-647 (2) until the sur-
face is in line with the spring length specification
mark on the threaded stud and the zero mark is on
the front.
3.Placespringoverstudonthetableandliftcom-
pressing lever to set tone device.
4. Pull on torque wrench (beam or dial type) until ping
is heard. Take reading on torque wrench at this
instant. Multiply this reading by two. This will give
the spring load at test length.
5. Compare reading to the specification. Discard the springs that do not meet specifications.
STANDARD PROCEDURE - VALVE SPRING/SEAL SERVICE IN-CAR
1. Disconnect negative battery cable.
2. Disconnect secondary ignition wires and remove
spark plugs.
3. Remove cylinder head cover(s) (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
4. Rotate crankshaft until No. 1 piston is at TDC on
compression stroke.
5. Remove rocker arms with pivots. The rocker arms
should not be disturbed and remain on pivot block.
6. With air hose attached to spark plug adapter
installed in No. 1 spark plug hole, apply 620.5 -
689 kPa (90 - 100 psi) air pressure. This is to hold
valves into place while servicing components.
CAUTION: Place a suitable shop towel around the
valve spring being serviced to prevent the valve
retaining locks from entering the engine once the
valve spring is compressed.
7. Using valve spring compressor MD998772-A with
insert 6716-A (1), compress valve spring (2) and
remove valve retaining locks.
8. Release valve spring compressor (1).
9. Remove valve spring and retainer.
10. Remove valve seal.
NOTE: Black valve seals are intake. Brown valve seals are exhaust.

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.