2006 DODGE RAM SRT-10 fuel tank removal

1. Remove fuel tank filler tube cap.
2. Perform fuel system pressure release procedure.
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY -
STANDARD PROCEDURE)
3. Remove negative battery cable at battery.
4. Remove flex tube (air cleaner housing to engine).
5. Remove air resonator box at throttle body.
6. Disconnect electrical connectors at all 8 fuel injec-
tors. Push red colored slider away from injector (1).
While pushing slider, depress tab (2) and remove
connector (3) from injector. The factory fuel injec-
tion wiring harness is numerically tagged (INJ 1,
INJ 2, etc.) for injector position identification. If har-
ness is not tagged, note wiring location before
removal.
7. Disconnect electrical connectors at all throttle body
sensors.
8. Disconnect fuel supply tube quick connect fitting at
the fuel rail, (Refer to14 - FUEL SYSTEM/FUEL
DELIVERY/QUICK CONNECT FITTING - STAN-
DARD PROCEDURE).
9. Remove four fuel rail mounting bolts (1) and hold-
down clamps.
10. Gently rock and pullleftside of fuel rail until fuel
injectors just start to clear machined holes in
intake manifold. Gently rock and pullrightside of
rail until injectors just start to clear intake manifold
head holes. Repeat this procedure (left/right) until
all injectors have cleared machined holes.
11. Remove fuel rail (with injectors attached) from
engine.
12. If fuel injectors are to be removed, (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/FUEL INJEC-
TOR - REMOVAL).

TA N K - F U E L
DESCRIPTION
The fuel tank is constructed of a plastic material. Its main functions are for fuel storage and for placement of the fuel
pump module, and (if equipped) certain ORVR components.
OPERATION
All models pass a full 360 degree rollover test without fuel leakage. To accomplish this, fuel and vapor flow controls
are required for all fuel tank connections.
Two check (control) valves are mounted into the top of the fuel tank. Refer to Fuel Tank Check Valve for additional
information.
An evaporation control system is connected to the fuel tank to reduce emissions of fuel vapors into the atmosphere.
When fuel evaporates from the fuel tank, vapors pass through vent hoses or tubes to a charcoal canister where
they are temporarily held. When the engine is running, the vapors are drawninto the intake manifold. Certain mod-
els are also equipped with a self-diagnosing system using a Leak DetectionPump (LDP) or NVLD Pump, and/or an
On-Board Refueling Vapor Recovery (ORVR) system. Refer to Emission Control System for additional information.
REMOVAL- EXCEPT DIESEL
1. Disconnect and separate fuel vent line (1) from fuel fill bezel (2).

8. Remove two fuel tank strap nuts (5) and remove both tank support straps (4).
9. Continue to lower tank for removal.
10. If fuel tank is to be replaced, remove fuel pump module from tank. Refer to Fuel Pump Module Removal/In-
stallation procedures.
INSTALLATION - EXCEPT DIESEL
1. If fuel tank is to be replaced, install fuel pump mod-
ule into tank. Refer to Fuel Pump Module Removal/
Installation procedures.
2. Disconnect clamps and remove rubber fuel fill hose
and fuel vent hose at fuel fill tube. Install these two
hoses to two fuel tank fittings. Rotate hoses until
paint marks (2) on hoses line up with alignment
marks (1). Tighten both clamps.

FILTER - INLET
REMOVAL
The fuel pump inlet filter (strainer) is located on the
bottom of the fuel pump module (1). The fuel pump
module is located inside of fuel tank.
1. Remove fuel tank. Refer to Fuel Tank Removal/In-
stallation.
2. Remove fuel pump module. Refer to Fuel Pump
Module Removal/Installation.
3. Remove filter by carefully prying 2 lock tabs (2) at
bottom of module with 2 screwdrivers. Filter is
snapped to module.
4. Clean bottom of pump module.
INSTALLATION
The fuel pump inlet filter (strainer) is located on the bottom of the fuel pump module. The fuel pump module is
located inside of fuel tank.
1. Snap new filter to bottom of module. Be sure o-ring is in correct position.
2. Install fuel pump module. Refer to Fuel Pump Module Removal/Installation.
3. Install fuel tank. Refer to Fuel Tank Removal/Installation.

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FUEL DELIVERY - DIESEL
DESCRIPTION - DIESEL FUEL SYSTEM ....... 105
STANDARD PROCEDURE
WATER DRAINING AT FUEL FILTER ......... 106
CLEANING FUEL SYSTEM PARTS .......... 106
FUEL SYSTEM PRIMING................... 106
DRAINING FUEL TANK - DIESEL............ 107
SPECIFICATIONS
FUEL INJECTOR FIRING ORDER - DIESEL . . 107
TORQUE .................................. 107
SPECIAL TOOLS
DIESEL FUEL SYSTEM . .................... 109
FILTER - FUEL / WATER SEPARATOR
DESCRIPTION ............................... 111
OPERATION ................................. 111
REMOVAL ................................... 111
INSTALLATION .............................. 113
HEATER-FUEL
DESCRIPTION ............................... 115
OPERATION ................................. 115
DIAGNOSIS AND TESTING
FUEL HEATER ............................. 115
REMOVAL ................................... 116
PUMP - FUEL INJECTION
DESCRIPTION ............................... 117
OPERATION ................................. 117
DIAGNOSIS AND TESTING
FUEL INJECTION PUMP TIMING ............ 117
REMOVAL ................................... 117
INSTALLATION .............................. 120
SENSOR - FUEL LEVEL SENDING UNIT
DESCRIPTION ............................... 124
OPERATION ................................. 124
REMOVAL
REMOVAL/INSTALLATION .................. 124
LINES - FUEL
DESCRIPTION ............................... 125
OPERATION ................................. 125DIAGNOSIS AND TESTING
HIGH-PRESSURE FUEL LINE LEAKS........ 125
REMOVAL ................................... 126
INSTALLATION .............................. 127
SENSOR - FUEL PRESSURE
DESCRIPTION ............................... 129
OPERATION ................................. 129
REMOVAL ................................... 129
INSTALLATION .............................. 129
VALVE - FUEL PRESSURE LIMITING
DESCRIPTION ............................... 130
OPERATION ................................. 130
REMOVAL ................................... 130
INSTALLATION .............................. 131
TA N K - F U E L
DESCRIPTION ............................... 132
REMOVAL ................................... 132
INSTALLATION .............................. 133
MODULE - FUEL TANK
DESCRIPTION ............................... 134
OPERATION ................................. 134
REMOVAL ................................... 134
INSTALLATION .............................. 134
PUMP - FUEL TRANSFER
DESCRIPTION ............................... 136
OPERATION ................................. 136
REMOVAL ................................... 136
INSTALLATION .............................. 136
VALVE - CASCADE OVERFLOW
DESCRIPTION ............................... 137
OPERATION ................................. 137
SENSOR-WATER IN FUEL
DESCRIPTION ............................... 138
OPERATION ................................. 138
REMOVAL ................................... 138
CIRCUIT - FUEL DRAIN
OPERATION ................................. 139

Fuel enters the system from the electric fuel transfer (lift) pump, which is located inside of the fuel tank and attached
to the fuel tank module (the fuel transfer pump is no longer attached to the engine). Fuel is forced through the fuel
filter element and then enters the Fuel Pump/Gear Pump, which is attached to the rear of the fuel injection pump.
The Fuel Pump/Gear Pump is a low-pressure pump and produce pressures ranging from 551.5 kpa (80 psi) to 1241
kpa (180) psi. Fuel then enters the fuel injection pump. Low pressure fuel is then supplied to the FCA (Fuel Control
Actuator).
The FCA is an electronically controlled solenoid valve. The ECM controls the amount of fuel that enters the high-
pressure pumping chambers by opening and closing the FCA based on a demanded fuel pressure. The FPS (Fuel
Pressure Sensor) on the fuel rail monitors the actual fuel pressure and provides it as an input to the ECM. When
the actuator is opened, the maximum amount of fuel is being supplied to the fuel injection pump. Any fuel that does
not enter the injection pump is directed to the overflow valve. The overflow valve regulates how much excess fuel
is used for lubrication of the pump and how much is returned to the tank through the drain manifold.
Fuel entering the injection pump is pressurized to between 300-1600 bar (4351-23,206 psi) by three radial pumping
chambers. The pressurized fuel is then supplied to the fuel rail.
STANDARD PROCEDURE
WATER DRAINING AT FUEL FILTER
Refer to Fuel Filter/Water Separatorremoval/installation for procedures.
CLEANING FUEL SYSTEM PARTS
CAUTION: Cleanliness cannot be overemphasized when handling or replacingdieselfuelsystemcompo-
nents. This especially includes the fuel injectors, high-pressure fuel lines and fuel injection pump. Very tight
tolerances are used with these parts. Dirt contamination could cause rapid part wear and possible plugging
of fuel injector nozzle tip holes. This in turn could lead to possible engine misfire. Always wash/clean any
fuel system component thoroughly before disassembly and then air dry. Capor cover any open part after
disassembly. Before assembly, examine each part for dirt, grease or othercontaminants and clean if nec-
essary. When installing new parts, lubricate them with clean engine oil orclean diesel fuel only.
FUEL SYSTEM PRIMING
A certain amount of air becomes trappedin the fuel system when fuel system components on the supply and/or
high-pressure side are serviced or replaced. Fuel system priming is accomplished using the electric fuel transfer (lift)
pump.
Servicing or replacing fuel system components will not require fuel systempriming.
The fuel transfer (lift) pump is self-priming: When the key is first turnedon (without cranking engine), the pump
operates for approximately 1 to 2 second and then shuts off (Note: When ambient temperatures are cold enough to
cause the intake air heaters to operate, the fuel lift pump will operate during the entire intake air pre-heat cycle).
The pump will also operate for up to 25 seconds after the starter is quickly engaged, and then disengaged without
allowing the engine to start. The pump shuts off immediately if the key is onand the engine stops running.
1. Turn key to CRANK position and quickly release key to ON position before engine starts. This will operate fuel
transfer pump for approximately 25 seconds.
2. Crank engine. If the engine does not start after 25 seconds, turn key to OFF position, and leave it off for at least
5 seconds. Repeat previous step until engine starts.
3. Fuel system priming is now completed.
4. Attempt to start engine. If engine will not start, proceed to following steps.When engine does start, it may run
erratically and be noisy for a few minutes. This is a normal condition.
CAUTION: Do not engage the starter motor for more than 30 seconds at a time. Allow two minutes between
cranking intervals.
5. Perform previous fuel priming procedure steps using fuel transfer pump. Be sure fuel is present at fuel tank.
6. Crank the engine for 30 seconds at a time to allow fuel system to prime.

PUMP - FUEL INJECTION
DESCRIPTION
A Robert Bosch high-pressure fuel injection pump is used. The pump is attached to the back of the timing gear
housing at the left /front side of the engine.
OPERATION
The fuel injection pump supplies high pressure to the fuel rail independent of engine speed. This high pressure is
then accumulated in the fuel rail. High pressure fuel is constantly supplied to the injectors by the fuel rail. The
Engine Control Module (ECM) controls the fueling and timing of the engine by actuating the injectors.
Fuel enters the system from the electric fuel transfer (lift) pump, which is located in the fuel tank. Fuel is forced
through the fuel filter element and then enters the Fuel Pump/Gear Pump, which is attached to the rear of the fuel
injection pump. The Fuel Pump/Gear Pump is a low-pressure pump and producepressures ranging from 551.5 kpa
(80 psi) to 1241 kpa (180) psi. Fuel then enters the fuel injection pump. Lowpressure fuel is then supplied to the
FCA (Fuel Control Actuator).
The FCA is an electronically controlled solenoid valve. The ECM controls the amount of fuel that enters the high-
pressure pumping chambers by opening and closing the FCA based on a demanded fuel pressure. The FPS (Fuel
Pressure Sensor) on the fuel rail provides the actual fuel pressure. When the actuator is opened, the maximum
amount of fuel is being supplied to the fuel injection pump. Any fuel that does not enter the injection pump is
directed to the cascade overflow valve. The cascade overflow valve regulates how much excess fuel is used for
lubrication of the pump and how much is returned to the tank through the drain manifold.
Fuel entering the injection pump is pressurized to between 300-1600 bar (4351-23206 psi) by three radial pumping
chambers. The pressurized fuel is then supplied to the fuel rail.
DIAGNOSIS AND TESTING
FUEL INJECTION PUMP TIMING
With the Bosch injection pump, there are no mechanical adjustments neededor necessary to accomplish fuel injec-
tion timing. All timing and fuel adjustments are electrically made by the engine mounted Engine Control Module
(ECM).
REMOVAL
CAUTION: Cleanliness cannot be overemphasized when handling or replacingdieselfuelsystemcompo-
nents. This especially includes the fuel injectors, high-pressure fuel lines and fuel injection pump. Very tight
tolerances are used with these parts. Dirt contamination could cause rapid part wear and possible plugging
of fuel injector nozzle tip holes. This in turn could lead to possible engine misfire. Always wash/clean any
fuel system component thoroughly before disassembly and then air dry. Capor cover any open part after
disassembly. Before assembly, examine each part for dirt, grease or othercontaminants and clean if nec-
essary. When installing new parts, lubricate them with clean engine oil orclean diesel fuel only.

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). The fuel transfer (lift) pump is also attached to the
fuel pump module.
OPERATION
For Fuel Gauge Operation:A constant input voltage source of about 12 volts (battery voltage) is supplied to the
resistor track on the fuel gauge sending unit. This is fed directly from theEngine Control Module (ECM).NOTE: For
diagnostic purposes, this 12V power source can only be verified with the circuit opened (fuel tank module
electrical connector unplugged). With the connectors plugged, output voltages will vary from about .6 volts
at FULL, to about 7.0 volts at EMPTY.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 returned back to the
ECM through the sensor return circuit.
Both of the electrical circuits between the fuel gauge sending unit and theECM are hard-wired (not multi-plexed).
After the voltage signal is sent from the resistor track, and back to the ECM, the ECM 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.
REMOVAL
REMOVAL/INSTALLATION
For diesel removal and installation procedures, refer to the gas section of Fuel System/Fuel Delivery. See Fuel
Level Sending Unit/Sensor Removal/Installation.