2006 DODGE RAM SRT-10 fuel pump

8. Connect electrical connector to top of fuel pump module.
9. Connect necessary emission vent lines to leak pump and EVAP canister (4)and/or (5).
10. Connect fuel supply line (2) to fuel pump module (1).
11. Connect necessary emission vent lines from check valves (3) and/or (7)at top of tank.
12. Connect fuel vent line (1) to fuel fill bezel (2).
13. Fill fuel tank with fuel.
14. Start engine and check for fuel leaks near top of module.

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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PEDAL - ACCELERATOR
REMOVAL .................................... 46
INSTALLATION ............................... 46
SENSOR-ACCELERATOR PEDAL POSITION
DESCRIPTION ................................ 47
OPERATION .................................. 47
REMOVAL .................................... 47
INSTALLATION ............................... 48
SENSOR-CRANKSHAFT POSITION
DESCRIPTION
3.7L V-6 .................................... 49
4.7L V-8 .................................... 49
5.7L V-8 .................................... 50
OPERATION
3.7L V-6 .................................... 50
4.7L V-8 .................................... 51
5.7L V-8 .................................... 51
REMOVAL
3.7L V-6 .................................... 52
4.7L V-8 .................................... 52
5.7L V-8 .................................... 53
8.3L - SRT-10 ............................... 53
INSTALLATION
3.7L V-6 .................................... 54
4.7L V-8 .................................... 55
5.7L V-8 .................................... 55
8.3L - SRT-10 ............................... 55
INJECTOR - FUEL
DESCRIPTION ................................ 56
OPERATION
FUEL INJECTOR ............................ 56
PCM OUTPUT .............................. 56
REMOVAL
3.7/4.7/ 5.7L ................................ 57
8.3L - SRT-10 ............................... 57
INSTALLATION
3.7/ 4.7/ 5.7L ............................... 60
8.3L - SRT-10 ............................... 60
RELAY - FUEL PUMP
DESCRIPTION ................................ 61
OPERATION .................................. 61
REMOVAL .................................... 61
INSTALLATION ............................... 61
MOTOR-IAC
DESCRIPTION
3.7L, 4.7L, 5.7L ............................. 62
8.3L - SRT-10 ............................... 63
OPERATION
3.7L V-6/4.7L V-8 ............................ 63
REMOVAL
3.7L V-6 .................................... 644.7L V-8 .................................... 65
5.7L V-8 .................................... 65
8.3L - SRT-10 ............................... 65
INSTALLATION
3.7L V-6 .................................... 66
4.7L V-8 .................................... 66
5.7L V-8 .................................... 66
8.3L - SRT-10 ............................... 67
SENSOR - INLET AIR TEMPERATURE
REMOVAL — 8.3L ............................. 68
INSTALLATION ............................... 68
SENSOR-INTAKE AIR TEMPERATURE
DESCRIPTION
3.7L V-6 .................................... 69
4.7L V-8 .................................... 69
5.7L V-8 .................................... 70
OPERATION .................................. 70
REMOVAL
3.7L V-6 .................................... 71
4.7L V-8 .................................... 72
5.7L V-8 .................................... 73
INSTALLATION
3.7L V-6 .................................... 74
4.7L V-8 .................................... 75
5.7L V-8 .................................... 75
SENSOR-MAP
DESCRIPTION
3.7L V-6 .................................... 76
4.7L V-8 .................................... 76
5.7L V-8 .................................... 77
8.3L - SRT-10 ............................... 77
OPERATION .................................. 77
REMOVAL
3.7L V-6 .................................... 79
4.7L V-8 .................................... 80
5.7L V-8 .................................... 80
8.3 L - SRT-10 .............................. 81
INSTALLATION
3.7L V-6 .................................... 81
4.7L V-8 .................................... 82
5.7L V-8 .................................... 83
8.3L - SRT-10 ............................... 83
SENSOR - OXYGEN
DESCRIPTION ................................ 84
REMOVAL .................................... 84
INSTALLATION ............................... 85
SWITCH-PTO
DESCRIPTION ................................ 86
OPERATION .................................. 86
THROTTLE BODY
DESCRIPTION ................................ 87

RELAY - FUEL PUMP
DESCRIPTION
The 5–pin, 12–volt, fuel pump relay is located in the Power Distribution Center (PDC). Refer to the label on the PDC
cover for relay location.
OPERATION
The Powertrain Control Module (PCM) energizes the electric fuel pump through the fuel pump relay. The fuel pump
relay is energized by first applying battery voltage to it when the ignition key is turned ON, and then applying a
ground signal to the relay from the PCM.
Whenever the ignition key is turned ON, the electric fuel pump will operate. But, the PCM will shut-down the ground
circuit to the fuel pump relay in approximately 1–3 seconds unless the engine is operating or the starter motor is
engaged.
REMOVAL
The fuel pump relay is located in the Power Distribu-
tion Center (PDC) (2). Refer to label on PDC cover for
relay location.
1. Remove PDC cover.
2. Remove relay from PDC.
3. Check condition of relay terminals and PDC con-
nector terminals for damage or corrosion. Repair if
necessary before installing relay.
4. Check for pin height (pin height should be the
same for all terminals within the PDC connector).
Repair if necessary before installing relay.
INSTALLATION
The fuel pump relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay loca-
tion.
1. Install relay to PDC.
2. Install cover to PDC.

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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 DELIVERY - DIESEL
DESCRIPTION - DIESEL FUEL SYSTEM
WARNING: High-pressure fuel lines deliver diesel
fuel under extreme pressure from the injection
pump to the fuel injectors. This may be as high as
160,000 kpa (23,206 psi). Use extreme caution
when inspecting for high-pressure fuel leaks.
Inspect for high-pressure fuel leaks with a sheet of
cardboard. High fuel injection pressure can cause
personal injury if contact is made with the skin.
The fuel system used on the Cummins engine is an electronically controlled, Bosch HPCR (High-Pressure Common
Rail) system. The HPCR system consists of five main components:
Electric Fuel Transfer (lift) Pump Located in the Fuel Tank
Fuel Pump/Gear Pump (attached to fuel injection pump)
High-Pressure Fuel Injection Pump
Fuel Injection Rail
Fuel Injectors
Also to be considered as part of the overall fuel system are:
Accelerator Pedal
Air Cleaner Housing/Element
Check Valve Banjo Fitting at Rear of Cylinder Head
Fuel Connector Tubes
Fuel Drain Manifold (passage)
Fuel Drain Valve (at filter)
Fuel Filter/Water Separator
Fuel Heater
Fuel Heater Relay
Fuel Transfer Pump Relay
Fuel Level (gauge) Sending Unit
Fuel Pressure Limiting Valve
Fuel Tank
Fuel Tank Module (containing a fuel gauge sending unit, separate fuel filter located at bottom of tank module,
and fuel transfer pump)
Fuel Tank Filler/Vent Tube Assembly
Fuel Tank Filler Tube Cap
Fuel Tubes/Lines/Hoses
High-Pressure Fuel Injector Lines
In-Tank Fuel Filter (at bottom of fuel tank module)
Low-Pressure Fuel Supply Lines
Low-Pressure Fuel Return Lines
Overflow Valve
Quick-Connect Fuel Line Fittings
Accelerator Pedal Position Sensor (APPS) Located in Cab
Water Draining (maintenance)
Water-In-Fuel (WIF) Sensor
Screened Banjo Bolt (22)
The fuel injection pump supplies high pressure to the fuel rail independent of engine speed. This high pressure fuel
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 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.

WARNING: The fuel injection pump supplies extremely high fuel pressure toeach individual injector
through the high-pressure lines. Fuel under this amount of pressure can penetrate the skin and cause per-
sonal injury. Wear safety goggles and adequate protective clothing. Do not loosen fuel fittings while engine
is running.
WARNING: Engine may start while cranking starter motor.
DRAINING FUEL TANK - DIESEL
Due to a one-way check valve installed into the fuel fill opening fitting atthe tank, the tank cannot be drained con-
ventionally at the fill cap.
1. Raise vehicle.
2. If vehicle is equipped with 4 doors and a 6 foot (short) box, remove left-rear tire/wheel.
3. Thoroughly clean area at top of fuel tank around fuel tank module.
4. Loosen clamp and disconnect rubber fuel fill hose at tank.
5. Drain fuel tank by attaching drain hose from an approved diesel fuel draining station to the fuel fill fitting of tank.
SPECIFICATIONS
FUEL INJECTOR FIRING ORDER - DIESEL
1–5–3–6–2–4
TORQUE
DESCRIPTION N-m Ft. Lbs. In. Lbs.
Crankshaft Position
Sensor980
Camshaft Position Sensor 9 - 80
Engine Coolant
Temperature Sensor18 13 160
Rear Engine Lift Bracket
Bolts77 56 -
Fuel Connector Nut at
Cylinder Head50 37 -
Fuel Filler Hose Clamp at
Ta n k3-27
Fuel Filler Housing-to-
Body Screws2-17
Fuel Filter Lid 34 25 -
Fuel Filter Drain Valve
Screws1.5 - 14
Fuel Heater Element
Screws1.5 - 14
Fuel Line Banjo Fitting
Bolts24 18 -
Screened Banjo Bolt 24 18 -
Fuel Line Banjo Fitting
Bolts at Fuel Filter
Housing24 18 -