2006 DODGE RAM SRT-10 fuel cap

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 -

SPECIAL TOOLS
DIESELFUELSYSTEM
FUEL PRESSURE TEST ADAPTER - # 9012
FUEL PRESSURE TEST ADAPTER - #9014
FUEL INJECTOR REMOVER - #9010
PRESSURE CAP - #9011
FUEL PRESSURE TEST ADAPTER - #9013
FUEL INJECTOR TUBE (CONNECTOR) REMOVER -
#9015
LOCKRING REMOVER/INSTALLER #9340

7.Fuel Heater Element Replacement:The heater
element (2) is located in the fuel filter housing.
a. Remove fuel filter. See previous steps.
b. Disconnect electrical connector.
c. Remove two T-15 Torx head mounting screws
(3) from fuel heater element.
d. Remove fuel heater.
8.Drain Valve Replacement:The drain valve
assembly (9) is located on the side of the fuel filter
housing.
a. Disconnect drain hose (7) from the fuel drain
valve.
b. Remove 4 drain valve mounting screws (T-15
Torx head) (8).
c. Remove drain valve from filter housing.
9. Remove the screened banjo bolt (9) that is located
on the bottom of the fuel filter housing. It attaches
the Injection Pump supply line to the fuel filter
housing.
INSTALLATION
Refer to maintenance schedules for recommended fuel filter replacement intervals.
1. Thoroughly clean inside of filter housing, filter cap and all related components.
2.Fuel Filter:
a.The engine has a self-priming low-pressure fuel system. Refer to StandardProcedures-Fuel System
Priming.
b. Install new O-ring to canister lid and lubricate O-ring with clean engine oil.
c. Position new element to canister lid. Place this assembly into canisterby rotating clockwise.
d. Tighten cap to 34 Nꞏm (25 ft. lbs.) torque. Do not overtighten cap.
3.Water-In-Fuel (WIF) Sensor:

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.

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 hanging loose within timing gear cover.
12. Remove 3 injection pump mounting nuts (6) , and remove pump from engine.
INSTALLATION
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.

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 from both
batteries. Cover and isolate ends of cables.
2. Thoroughly clean fuel lines at both ends.
3. If removing fuel line at either No. 1 or No. 2 cylin-
der, the intake manifold air heater elements must
first be removed from top of intake manifold. Refer
to Intake Air Heater Removal / Installation for pro-
cedures.
4. If removing fuel line at No. 6 cylinder, a bracket (1)
is located above fuel line connection at cylinder
head. Two bolts secure this bracket to rear of cyl-
inder head. The upper bolt hole is slotted. Loosen
(but do not remove) these 2 bracket bolts. Tilt
bracket down to gain access to No. 6 fuel line con-
nection.
5. Remove engine lift bracket (if necessary).
6. Remove necessary insulated fuel line support
clamps (2) at intake manifold. DO NOT remove
insulators from fuel lines.
7. Place shop towels around fuel lines at fuel rail and
injectors. If possible, do not allow fuel to drip down
side of engine.
CAUTION: When loosening or tightening high-pressure lines attached to a separate fitting , use a back-up
wrench on fitting. Do not allow fitting to rotate. Damage to both fuel line and fitting will result.

VALVE - FUEL PRESSURE LIMITING
DESCRIPTION
The fuel pressure limiting valve is located on the top of the fuel rail.
OPERATION
Fuel pressure at the fuel rail is monitored by the fuel rail pressure sensor. If fuel pressure becomes excessive, the
pressure limiting valve opens and vents excess pressure into the fuel draincircuit.
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.
The fuel pressure limiting valve (3) is located on the
top of the fuel rail.
1. Thoroughly clean area at pressure limiting valve.
2. Remove banjo bolt (2) at banjo fitting.
3. Remove pressure limiting valve from fuel rail.

ACTUATOR - FUEL CONTROL
DESCRIPTION
The Fuel Control Actuator (FCA) is located at the rear
of the high-pressure, fuel injection pump (2).
OPERATION
The Fuel Control Actuator (FCA) is an electronically controlled solenoidvalve. The ECM controls the amount of fuel
that enters the high-pressure pumping chambers by opening and closing theFCA based on a demanded fuel pres-
sure. When the FCA is opened, the maximum amount of fuel is being supplied tothe fuel injection pump. Any fuel
that does not enter the injection pump is directed to the cascade overflow valve. The cascade overflow valve reg-
ulates how much excess fuel is used for lubrication of the pump and how much is returned to the fuel tank through
the drain manifold.
An audible click from the FCA is normal when operating the key from the ON to the OFF position.
REMOVAL
1. Remove the cap srews and Fuel Control Actuator (FCA).
2. Twist and pull FCA to remove.
INSTALLATION
1. Lubricate the new Fuel Control Actuator (FCA) o-ring with clean oil before installation.
2. Turn the FCA in a clockwise direction while pressing it into the bore. Be sure that the FCA flange is flush with the
mounting surface on the Fuel Injection Pump.
3. Install the capscrews by hand.
4. Then tighten capscrews to 7Nm (62 in-lbs).