2006 DODGE RAM SRT-10 fuel pump

COVER-TIMING CHAIN
REMOVAL
1. Disconnect negative battery cable.
2. Disconnect throttle body air inlet duct at the throttle
body, CCV hose, disconnect the IAT sensor and
remove air cleaner housing cover (Refer to 9 -
ENGINE/AIR INTAKE SYSTEM - REMOVAL).
3. Remove the oil indicator tube (1) fastener at the
right cylinder head cover.
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. Drain engine oil and remove oil filter (Refer to 9 -
ENGINE/LUBRICATION/OIL - STANDARD PRO-
CEDURE).
8. Drain power steering.
9. Disconnect the cooling fan return hose at radiator
fan.
10. Disconnect the radiator fan pressure hose to
power steering rack.
11. Disconnect the power steering hose to power steering pump.
12. Separate the A/C hose from the radiator fan module.
13. Remove the lower radiator hoses.
14. Remove the front frame cross member (Refer to 13 - FRAME & BUMPERS/FRAME/FRONT CROSSMEMBER
- REMOVAL).
15. Remove the flywheel inspection cover.
NOTE: Capture and properly dispose of any fuel spillage.
16. Disconnect oil cooler line at the timing cover using Special Tool 9005 (Refer to 9 - ENGINE/LUBRICATION/OIL
COOLER & LINES - STANDARD PROCEDURE).
17. Separate the oil cooler coolant hose from the timing cover.

FUEL SYSTEM
TABLE OF CONTENTS
page page
FUEL DELIVERY - GAS....................1
FUEL INJECTION - GAS...................44FUEL DELIVERY - DIESEL................104
FUEL INJECTION - DIESEL...............140
page page
FUEL DELIVERY - GAS
DESCRIPTION ................................. 2
OPERATION ................................... 4
STANDARD PROCEDURE
STANDARD PROCEDURE - FUEL SYSTEM
PRESSURE RELEASE........................ 4
STANDARD PROCEDURE - DRAINING FUEL
TANK - EXCEPT DIESEL...................... 5
SPECIFICATIONS
FUEL SYSTEM PRESSURE ................... 5
TORQUE - EXCEPT DIESEL.................. 5
SPECIAL TOOLS
FUEL SYSTEM.............................. 8
FUEL FILTER/PRESSURE REGULATOR
DESCRIPTION ................................. 9
OPERATION ................................... 9
SENSOR - FUEL LEVEL SENDING UNIT
DESCRIPTION ................................ 10
OPERATION .................................. 10
REMOVAL .................................... 10
INSTALLATION ................................ 11
LINES, FUEL
DESCRIPTION ................................ 12
FITTING-QUICK CONNECT
DESCRIPTION ................................ 13
STANDARD PROCEDURE - QUICK-CONNECT
FITTINGS .................................. 13
MODULE-FUEL PUMP
DESCRIPTION ................................ 19OPERATION .................................. 19
MODULE - FUEL PUMP
DESCRIPTION ................................ 20
OPERATION .................................. 20
REMOVAL .................................... 20
INSTALLATION ............................... 21
RAIL - FUEL
DESCRIPTION ................................ 22
OPERATION .................................. 22
REMOVAL
3.7L V-6 .................................... 22
4.7L V-8 .................................... 23
5.7L ....................................... 24
8.3L - SRT-10 ............................... 26
INSTALLATION
3.7L ....................................... 30
4.7L ....................................... 31
5.7L ....................................... 32
8.3L - SRT-10 ............................... 32
TA N K - F U E L
DESCRIPTION ................................ 34
OPERATION .................................. 34
REMOVAL- EXCEPT DIESEL ................... 34
INSTALLATION - EXCEPT DIESEL . ............. 38
FILTER - INLET
REMOVAL .................................... 43
INSTALLATION ............................... 43

FUEL DELIVERY - GAS
DESCRIPTION
The fuel delivery system consists of:
a fuel pump module containing the electric fuel pump, fuel filter/fuel pressure regulator, fuel gauge sending unit
(fuel level sensor) and a secondary fuel filter located at the bottom of thepump module
fuel tubes/lines/hoses
a combination fuel filter/fuel pressure regulator
quick-connect fittings
fuel injector rail
fuel tank
fuel tank filler/vent tube assembly
fuel tank filler tube cap
accelerator pedal
throttle cable
Certain fuel delivery components can be found in the following graphics:

OPERATION
Fuel is returned through the fuel pump module and back into the fuel tank through the fuel filter/fuel pressure reg-
ulator. A separate fuel return line from the engine to the tank is not used.
The fuel tank assembly consists of: the fuel tank, fuel pump module assembly, fuel pump module locknut/gasket,
and fuel tank check valve (refer to Fuel Tank Check Valve for information).
A fuel filler/vent tube assembly using apressure/vacuum,1/4 turn fuel filler cap is used. The fuel filler tube contains
a flap door located below the fuel fill cap.
Also to be considered part of the fuelsystem is the evaporation control system. This is designed to reduce the
emission of fuel vapors into the atmosphere. The description and functionof the Evaporative Control System is
found in Emission Control Systems.
Both fuel filters (at bottom of fuel pump module and within fuel pressure regulator) are designed for extended ser-
vice. They do not require normal scheduled maintenance. Filters should only be replaced if a diagnostic procedure
indicates to do so.
STANDARD PROCEDURE
STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE
Use following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port.
1. Remove fuel fill cap.
2. Remove fuel pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside
of PDC cover.
3. Start and run engine until it stalls.
4. Attempt restarting engine until it will no longer run.
5. Turn ignition key to OFF position.
CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within fuel rail. Do not
attempt to use following steps to relieve this pressure as excessive fuel will be forced into a cylinder cham-
ber.
6. Unplug connector from any fuel injector.
7. Attach one end of a jumper wire with alligator clips (18 gauge or smaller)to either injector terminal.

8. Connect other end of jumper wire to positive side of battery.
9. Connect one end of a second jumper wire to remaining injector terminal.
CAUTION: Powering an injector for more than a few seconds will permanentlydamage the injector.
10. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds.
11. Place a rag or towel below fuel line quick-connect fitting at fuel rail.
12. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings.
13. Return fuel pump relay to PDC.
14. One or more Diagnostic Trouble Codes (DTC’s) may have been stored in PCMmemory due to fuel pump relay
removal. The DRB
scantoolmustbeusedtoeraseaDTC.
STANDARD PROCEDURE - DRAINING FUEL TANK - EXCEPT DIESEL
WARNING: The fuel system may be under constant fuel pressure even with the engine off. This pressure
must be released before servicing fuel tank.
Two different procedures may be used to drain fuel tank: through the fuel fill fitting on tank, or using a diagnostic
scan tool to activate the fuel pump relay. Due to a one-way check valve installed into the fuel fill opening fitting at
the tank, the tank cannot be drained conventionally at the fill cap.
The quickest draining procedure involves removing the rubber fuel fill hose at the fuel tank.
As an alternative procedure, the electric fuel pump may be activated allowingtanktobedrainedatfuelrailcon-
nection. Refer to diagnostic scan tool for fuel pump activation procedures. Before disconnecting fuel line at fuel rail,
release fuel pressure. Refer to the Fuel System Pressure Release Procedure for procedures. Attach end of special
test hose tool number 6631 or 6539 at fuel rail disconnection (tool number 6631isusedon5/16”fuellineswhile
tool number 6539 is used on 3/8” fuel lines). Position opposite end of this hose tool to an approved gasoline drain-
ing station. Activate fuel pump and drain tank until empty.
If electric fuel pump is not operating, fuel must be drained through fuel fill fitting at tank. Refer to following proce-
dures.
1. Release fuel system pressure.
2. Raise vehicle.
3. Thoroughly clean area around fuel fill fitting and rubber fuel fill hoseat tank.
4. If vehicle is equipped with 4 doors and a 6 foot (short) box, remove left-rear tire/wheel.
5. Loosen clamp and disconnect rubber fuel fill hose at tank fitting. Usingan approved gas holding tank, drain fuel
tank through this fitting.
SPECIFICATIONS
FUEL SYSTEM PRESSURE
58 psi +/- 2 psi
TORQUE - EXCEPT DIESEL
DESCRIPTION N-m Ft. Lbs. In. Lbs.
Accelerator Pedal Bracket
Mounting12 - 105
Accelerator Pedal Position
Sensor Bracket-to-Battery
Tray Bolts3-30
Crankshaft Position
Sensor - 3.7L28 21 -
Crankshaft Position
Sensor - 4.7L28 21 -

DESCRIPTION N-m Ft. Lbs. In. Lbs.
Crankshaft Position
Sensor - 5.7L12 - 105 (+/-20)
Camshaft Position Sensor
-3.7L12 - 106
Camshaft Position Sensor
-4.7L12 - 106
Camshaft Position Sensor
-5.7L12 9 105 (+/-) 20
Engine Coolant
Temperature Sensor - 3.7L11 - 9 6
Engine Coolant
Temperature Sensor - 4.7L11 - 9 6
Engine Coolant
Temperature Sensor - 5.7L11 - 9 6
EVAP Canister- to-Bracket
Nuts8.5 - 75
EVAP Canister-to-Frame
Bolts34 25
Fuel Filler Hose Clamp at
Tank3-30
Fuel Filler Housing-to-
Body Screws2-17
Fuel Pump Module Lock
Ring54 40 -
Fuel Rail Mounting Bolts -
3.7L11 -
100
Fuel Rail Mounting Bolts -
4.7L11 - 1 0 0
Fuel Rail Mounting Bolts -
5.7L11 - 1 0 0
Fuel Rail Mounting Bolts -
8.3L12 - 105
Fuel Tank Mounting Straps 41 30 -
IAC Motor Mounting
Screws - 3.7L7-60
IAC Motor Mounting
Screws - 4.7L7-60
Leak Detection Pump
Mounting Bolt8.5 - 75
Map Sensor Mounting
Screws - 3.7L3-25
Map Sensor Mounting
Screws - 4.7L3-25
PCM-to-Mounting Bracket
Mounting Screws4-35
Power Steering Pressure
Switch - 3.7L14-22 - 124-195
Power Steering Pressure
Switch - 4.7L14-22 - 124-195

FUEL FILTER/PRESSURE REGULATOR
DESCRIPTION
A combination fuel filter and fuel pressure regulator (3)
is used on all engines. It is located on the top of the
fuel pump module. A separate frame mounted fuel fil-
ter is not used with any engine.
Both fuel filters (at bottom of fuel pump module and
within fuel pressure regulator) are designed for
extended service. They do not require normal sched-
uled maintenance. Filters should only be replaced if a
diagnostic procedure indicates to do so.
OPERATION
Fuel Pressure Regulator Operation:The pressure regulator is a mechanical device that is not controlled by
engine vacuum or the Powertrain Control Module (PCM).
The regulator is calibrated to maintain fuel system operating pressure ofapproximately 58 ± 2 psi at the fuel injec-
tors. It contains a diaphragm, calibrated springs and a fuel return valve.The internal fuel filter is also part of the
assembly.
Fuel is supplied to the filter/regulator by the electric fuel pump throughan opening tube at the bottom of filter/reg-
ulator.
The regulator acts as a check valve to maintain some fuel pressure when the engine is not operating. This will help
to start the engine. A second check valve is located at the outlet end of the electric fuel pump.Refer to Fuel Pump
- Description and Operation for more information.
If fuel pressure at the pressure regulator exceeds approximately 60 psi, an internal diaphragm opens and excess
fuel pressure is routed back into the tank through the bottom of pressure regulator.
Both fuel filters (at bottom of fuel pump module and within fuel pressure regulator) are designed for extended ser-
vice. They do not require normal scheduled maintenance. Filters should only be replaced if a diagnostic procedure
indicates to do so.

SENSOR - FUEL LEVEL SENDING UNIT
DESCRIPTION
The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit
consists of a float, an arm, and a variable resistor track (card).
OPERATION
The fuel pump module has 4 different circuits (wires). Two of these circuits are used for the fuel gauge sending unit
for fuel gauge operation, and for certain OBD II emission requirements. The other 2 wires are used for electric fuel
pump operation.
For Fuel Gauge Operation:A constant current source is supplied to the resistor track on the fuel gauge sending
unit. This is fed directly from the Powertrain Control Module (PCM).NOTE: For diagnostic purposes, this 12V
power source can only be verified with the circuit opened (fuel pump moduleelectrical connector
unplugged). With the connectors plugged, output voltages will vary from about 0.6 volts at FULL, to about
8.6 volts at EMPTY (about 8.6 volts at EMPTY for Jeep models, and about 7.0 volts at EMPTY for Dodge
Truck models).The resistor track is used to vary the voltage (resistance) depending on fuel tank float level. As fuel
level increases, the float and arm move up, which decreases voltage. As fuel level decreases, the float and arm
move down, which increases voltage. The varied voltage signal is returnedback to the PCM through the sensor
return circuit.
Both of the electrical circuits between the fuel gauge sending unit and thePCM are hard-wired (not multi-plexed).
After the voltage signal is sent from the resistor track, and back to the PCM, the PCM will interpret the resistance
(voltage) data and send a message across the multi-plex bus circuits to theinstrument panel cluster. Here it is
translated into the appropriate fuel gauge level reading. Refer to Instrument Panel for additional information.
For OBD II Emission Monitor Requirements:The PCM will monitor the voltage output sent from the resistor track
on the sending unit to indicate fuel level. The purpose of this feature is toprevent the OBD II system from recording/
setting false misfire and fuel systemmonitor diagnostic trouble codes. The feature is activated if the fuel level in the
tank is less than approximately 15 percent of its rated capacity. If equipped with a Leak Detection Pump (EVAP
system monitor), this feature will also be activated if the fuel level in the tank is more than approximately 85 percent
of its rated capacity.
REMOVAL
The fuel level sending unit (fuel level sensor) and float
assembly (7) is located on the side of the fuel pump
module.
1. Remove fuel pump module from fuel tank. Refer to
Fuel Pump Module Removal/Installation.
2. Disconnect 4–wire electrical connector (3) from fuel
pump module. Separate necessary sending unit
wiring from connector using terminal pick / removal
tool. Refer to Special Tools in 8W Wiring for tool
part numbers.