2006 DODGE RAM SRT-10 Service Repair Manual

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Page 2353 of 5267

DODGE RAM SRT-10 2006 Service Repair Manual REMOVAL
The fuel heater sensor/thermostat is located on the side of the fuel filterhousing. The fuel heater element is located
internal to the fuel filter housing. (Refer to 14 - FUEL SYSTEM/FUEL DELI

Page 2354 of 5267

DODGE RAM SRT-10 2006 Service Repair Manual 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

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.

Page 2355 of 5267

DODGE RAM SRT-10 2006 Service Repair Manual 1. Disconnect both negative battery cables at both
batteries. Cover and isolate ends of both cables.
2. Remove intake manifold air intake tube (above
injection pump) and its rubber connector hose (2).

Page 2356 of 5267

DODGE RAM SRT-10 2006 Service Repair Manual 5. Disconnect Fuel Control Actuator (FCA) electrical
connector (3) at rear of injection pump.
CAUTION: Whenever a fuel line fitting is con-
nected to a secondary fitting, always use a
back-upwrenchont

Page 2357 of 5267

DODGE RAM SRT-10 2006 Service Repair Manual 11. Attach C3428B, or L4407A (or equivalent) gear
puller (1) to pump drive gear with 2 bolts, and
separate gear from pump (a keyway is not used
on this particular injection pump). Leave drive
gear han

Page 2358 of 5267

DODGE RAM SRT-10 2006 Service Repair Manual 1. Inspect pump mounting surfaces at pump and
mounting flange and pilot bore for nicks, cuts or
damage. Inspect O-ring surfaces for nicks, cuts or
damage.
2. Clean injection pump mounting flange and p

Page 2359 of 5267

DODGE RAM SRT-10 2006 Service Repair Manual 9. Install drive gear access cover (2) using a 3/8”
drive ratchet. Access cover is threaded to timing
gear cover. Tighten to 8 Nꞏm (71 in. lbs.) torque.
10. Install fuel return line (injection pum

Page 2360 of 5267

DODGE RAM SRT-10 2006 Service Repair Manual 13. Connect Fuel Control Actuator (FCA) electrical
connector (3) to rear of injection pump.
14. Install intake manifold air intake tube (above injec-
tion pump). Tighten clamps.
15. Install accessory

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