2006 DODGE RAM SRT-10 engine

SENSOR-CAMSHAFT POSITION
DESCRIPTION
The Camshaft Position Sensor (CMP) on the 5.9L diesel engine is located below the fuel injection pump. It is bolted
to the back of the timing gear housing.
OPERATION
The diesel Camshaft Position Sensor (CMP) contains
a hall effect device. A rotating target wheel (tone-
wheel) for the CMP is located on the camshaft gear.
This hall effect device detects holes located on the
back side of the camshaft gear. As the camshaft gear
rotates, the holes pass the tip of the CMP.
When the leading edge of the hole passes the tip of
the CMP, the following occurs: The interruption of
magnetic field causes the voltage to switch high
resulting in a signal of approximately 5 volts.
When the trailing edge of the hole passes the tip of
the CMP, the following occurs: The change of the
magnetic field causes the signal voltage to switch low
to 0 volts.
The CMP (1) provides a signal to the Engine Control
Module (ECM) at all times when the engine is running.
TheECMusestheCMPinformationprimarilyon
engine start-up. Once the engine is running, the ECM
uses the CMP as a backup sensor for engine speed.
The Crankshaft Position Sensor (CKP) is the primary
engine speed indicator for the engine after the engine
is running.
REMOVAL
The Camshaft Position Sensor (CMP) on the 5.9L die-
sel engine is located (1) below the fuel injection pump.
It is bolted to the back of the timing gear housing (7).
1. Disconnect electrical connector at CMP sensor.
2. Remove sensor mounting bolt (6).
3. Carefully twist and pull the sensor from timing gear
housing.
4. Check condition of sensor O-ring.

INSTALLATION
1. Clean out machined hole in back of timing gear
housing.
2. Apply a small amount of engine oil to sensor O-ring
and sensor hole.
3. Install sensor into timing gear housing with a slight
rocking action. Do not twist sensor into position as
damagetoO-ringmayresult.
CAUTION: Before tightening sensor mounting bolt,
be sure sensor is completely flush to back of tim-
ing gear housing (cover). Remove (cover) if sensor
is not flush, damage to sensor mounting tang may
result.
4. Install mounting bolt and tighten. Torque to 9 Nꞏm
(80 in. lbs.).
5. Connect electrical connector (5) to sensor.

SENSOR-CRANKSHAFT POSITION
DESCRIPTION
The Crankshaft Position Sensor (CKP) on the diesel engine is attached at thefront/leftsideoftheenginenextto
the engine harmonic balancer (crankshaft damper).
OPERATION
The Crankshaft Position Sensor (CKP) (5) is the pri-
mary engine speed indicator for the engine after the
engine is running.
The CKP contains a hall effect device. A rotating,
notched target wheel (tonewheel) for the CKP is
located behind the engine harmonic balancer (2). This
hall effect device detects notches located on the tone-
wheel. As the tonewheel rotates, the notches pass the
tip of the CKP.
When the leading edge of the tonewheel notch passes
the tip of the CKP, the following occurs: The interrup-
tion of magnetic field causes the voltage to switch
high resulting in a signal of approximately 5 volts.
When the trailing edge of the tonewheel notch passes
the tip of the CKP, the following occurs: The change of
the magnetic field causes the signal voltage to switch
lowto0volts.
The Camshaft Position Sensor (CMP) also provides a
signal to the Engine Control Module (ECM) at all times
when the engine is running. The ECM uses this CMP
information primarily on engine start-up. Once the
engine is running, the ECM uses the CMP as a
backup sensor for engine speed.

REMOVAL
1. Raise and support vehicle
2. Disconnect electrical connector (4) at CKP sensor.
3. Remove 1 sensor mounting bolt (3).
4. Remove CKP sensor.
INSTALLATION
1. Position and install CKP sensor (5) to engine.
2. Install 1 sensor mounting bolt and tighten to 9 Nꞏm
(80 in. lbs.) torque.
3. Install electrical connector (4) to CKP sensor.

INJECTOR - FUEL
DESCRIPTION
Six individual, solenoid actuated high-pressure fuel
injectors are used. The injectors are vertically mounted
into a bored hole in the top of the cylinder head. This
bored hole is located between the intake/exhaust
valves.
High-pressure connectors, mounted into the side of the cylinder head, connect each fuel injector to each high-pres-
sure fuel line. The injector part number is laser-burned onto the injector. Failure to replace with the proper injector
will cause severe engine damage.

4. Remove valve cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL).
5. Remove all 12 fuel injector wire harness nuts (1) securing integrated wiring harness to all 6 fuel injectors.
6. Remove all 12 fuel injector wire harness nuts (1)
securing integrated wiring harness to all 6 fuel
injectors.
7. An integrated fuel injector wire harness / valve
cover gasket (2) is used. After all 12 nuts (1) have
been removed, remove this integrated gasket.
Before removing gasket, disconnect engine wiring
harness at both electrical connectors (3).
8. Remove necessary high pressure fuel line connecting the necessary fuelinjector rail to high pressure connector.
Refer to Fuel Line Removal for procedures.
9. A connector retainer (nut) is used on each connector tube. Remove this nut(s) by unthreading from cylinder
head.

3. The bottom of fuel injector is sealed to cylinder
head bore with a copper sealing washer (shim) (1)
of a certain thickness. A new shim (1) with correct
thickness must always be re-installed after remov-
ing injector. Measure thickness of injector shim (1).
Shim Thickness: 1.5 mm (.060”)
4. Install new shim (1) (washer) to bottom of injector.
Apply light coating of clean engine oil to washer.
This will keep washer in place during installation.
5. Install new o-ring to fuel injector. Apply small
amount of clean engine oil to O-ring and injector
bore.
6. Install injector into cylinder head with male (high-
pressure) connector port facing the intake manifold.
Push down on fuel injector mounting flange to
engage O-ring and seat injector.
7. Tightening Sequence:
a. Install fuel injector holdown clamp (mounting
flange) bolts. Be sure the clamp is perpendicular to the injector body.Do a preliminary tightening of these
bolts to 5 Nꞏm (44 in. lbs.) torque. This preliminary tightening insures the fuel injector is seated and
centered.
b. After tightening, relieve bolt torque, but leave both bolts threaded inplace.
c. Install high-pressure connector and retaining nut. Do a preliminary tightening to 15 Nꞏm (11 ft. lbs.) torque.
d. Alternately tighten injector holdown bolts to 10 Nꞏm (89 in. lbs.) torque.
e. Do a final tightening of the high-pressure connector and retaining nut.Tighten to 50 Nꞏm (37 ft. lbs.) torque.
8. Install integrated gasket
9. Connect injector solenoid wires and nuts to top of injectors. Tighten connector nuts to 1.25 Nꞏm (11 in. lbs.)
torque.Be very careful not to overtighten these nuts as damage to fuel injector willoccur.
10. Install exhaust rocker arm assembly. Refer to the Diesel Engine section.
11. Set exhaust valve lash. Refer to the Diesel Engine section.
12. Install fuel connector tube nut at cylinder head and tighten to 50 Nꞏm (37ft.lbs.).Be sure to use a secondary
back-up wrench on the connector nut (fitting) while torquing fuel line fitting.Refer to Fuel Line Installation
for additional information.
13. Install valve cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION).
14. Install breather assembly.
15. Connect negative battery cables to both batteries.

FUEL INJECTOR RAIL
DESCRIPTION
The fuel injector rail is bolted to the top of the intake manifold.
OPERATION
The fuel rail is used as a distribution device to supply high-pressure fuelto the high-pressure fuel lines.
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.
1. Disconnect both negative battery cables at both
batteries. Isolate ends of both cables.
2. Disconnect electrical connector at fuel pressure
sensor.
3. Remove banjo bolt at fuel limiting valve.
4. Disconnect necessary wiring harness retention
clips from intake manifold.
5. Lift 2 rubber covers to gain access to positive (+),
intake heater cable nuts. Remove 2 nuts and
remove 2 cables from studs.
6. Carefully remove 4 high-pressure fuel lines from
top of fuel rail. Note position of each line while
removing.Do not bend lines while removing.
CAUTION: WHEN LOOSENING OR TIGHTENING
HIGH-PRESSURE LINES ATTACHED TO A SEPA-
RATE FITTING, USE A BACK-UP WRENCH ON FIT-
TING. DO NOT ALLOW FITTING TO ROTATE.
DAMAGE TO BOTH FUEL LINE AND FITTING WILL
RESULT.
7. Carefully remove 2 high-pressure fuel lines at each end of fuel rail. Note position of each line while removing.Do
not bend lines while removing.(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL LINES - REMOVAL).
8. Remove fuel line connectinginjection pump to fuel rail.
9. Remove three injection rail mounting bolts.
10. Remove rail from top of intake manifold.