2006 DODGE RAM SRT-10 check engine

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.

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 -

FILTER - FUEL / WATER SEPARATOR
DESCRIPTION
The fuel filter/water separator assembly is located on left side of engineabove the starter motor. The assembly also
includes the fuel heater, Water-In-Fuel (WIF) sensor and a screened banjobolt attached at the bottom of the fuel
filter canister.
OPERATION
The fuel filter/water separator protects the fuel injection pump by removing water and contaminants from the fuel.
The construction of the filter/separator allows fuel to pass through it, but helps prevent moisture (water) from doing
so. Moisture collects at the bottom of the canister.
Refer to the maintenance schedules in the owners manual for the recommended fuel filter replacement intervals.
For draining of water from canister, refer to Fuel Filter/Water SeparatorRemoval/Installation section.
There is a screened banjo bolt that is attached at the bottom of the fuel filter canister. It provides additional filtering
for the high pressure fuel system components.
A Water-In-Fuel (WIF) sensor is attached to the side of fuel filter housing. Refer to Water-In-Fuel Sensor Descrip-
tion/Operation.
The fuel heater is installed into the top of the filter/separator housing.Refer to Fuel Heater Description/Operation.
REMOVAL
Refer to maintenance schedules in this manual, or the
Owner’s Manual for recommended fuel filter replace-
ment intervals.
Draining water from fuel filter/water separator
housing:
The housing drain valve (9) serves two purposes. One
is topartiallydrain the filter housing of excess water.
The other is tocompletelydrain the housing for fuel
filter, drain valve, heater element or water-in-fuel sen-
sor replacement.
The filter housing should be partially drained when-
ever the water-in-fuel warning lamp remains illumi-
nated. (Note that lamp will be illuminated for
approximately two seconds when ignition key is ini-
tially placed in ON position for a bulb check).
1. A drain hose (7) is located at the bottom of drain
valve. Place drain pan under drain hose.
2.With engine not running,rotate drain valve han-
dle counter-clockwise (rearward) to OPEN (DRAIN)
position. Hold drain valve open until all water and
contaminants have been removed and clean fuel
exits.
3. If drain valve, fuel heater element or Water-In-Fuel (WIF) sensor is being replaced, drain housing completely.
Dispose of mixture in drain pan according to applicable regulations.
4. After draining operation, rotate valve handle clockwise (forward) to the CLOSE position.

a. Install new o-ring seal to WIF sensor.
b. Apply a light film of clean oil to o-ring seal.
c. Install sensor into housing.
d. Tighten sensor to 2.5 Nꞏm (25 in. lbs.) torque.
e. Connect electrical connector to WIF sensor.
4.Fuel Heater Element:
a. Install fuel heater into fuel filter housing.
b. Install fuel heater thermostat onto the outside of the fuel filter housing.
c. Install fuel heater mounting screws and tighten to 1-1.5 Nꞏm (8 - 13 in. lbs.) torque.
d. Connect electrical connector to fuel heater thermostat.
e. Install new filter cover O-ring onto fuel filter housing cover and lubricate with clean engine oil.
f. Tighten fuel filter housing cover (lid) to 34 Nꞏm (25 ft. lbs.).
5.Drain Valve:
a. Install 2 new O-rings to valve.
b. Lubricate with silicon grease.
c. Installfueldrainvalve.
d. Install 4 mounting screws and tighten to 1–1.5 Nꞏm (8–13 in. lbs.) torque.
e. Connect drain hose to drain valve.
6. Install two new sealing washers to bolt.
7. Install screened banjo bolt Tighten to 24 Nꞏm (18 ft. lbs.)
8. Start engine and check for leaks.

HEATER-FUEL
DESCRIPTION
The fuel heater assembly is located on the side of the fuel filter housing and internal to the fuel filter housing .
The heater/element assembly is equipped with a temperature sensor (thermostat) that senses fuel temperature. This
sensor is attached to the fuel heater/element assembly.
OPERATION
The fuel heater is used to prevent diesel fuel from waxing during cold weather operation.
When the fuel temperature is below 45° ±8 F (7°C), the temperature sensor allows current to flow to the heater
element warming the fuel. When the fuel temperature is above 75° ±8 F (24°C), the sensor stops current flow to the
heater element.
Battery voltage to operate the fuel heater element is supplied from the ignition switch and through a solid stated
device in the IPM.The fuel heater element and
solid state device in IPMinstead offuel heater relayare not
computer controlled.
The heater element operates on 12 volts, 300 watts at 0° F (-18° C).
DIAGNOSIS AND TESTING
FUEL HEATER
The fuel heater is used to prevent diesel fuel from waxing during cold weather operation.
NOTE: The fuel heater element,
solid state device in IPMinstead offuel heater relayand fuel heater tem-
perature sensor are not controlled by the Engine Control Module (ECM).
A malfunctioning fuel heater can cause a wax build-up in the fuel filter/water separator. Wax build-up in the filter/
separator can cause engine starting problems and prevent the engine from revving up. It can also cause blue or
white fog-like exhaust. If the heater is not operating in cold temperatures, the engine may not operate due to fuel
waxing.
The fuel heater assembly is located on the side of fuel filter housing and internal to the fuel filter housing.
The heater assembly is equipped with a built-in fuel temperature sensor (thermostat) that senses fuel temperature.
When fuel temperature drops below 45° ± 8° F (7° C), the sensor allows current to flow to built-in heater element
to warm fuel. When fuel temperature rises above 75 °± 8° F (24° C), the sensorstops current flow to heater ele-
ment (circuit is open).
Voltage to operate fuel heater element is supplied from ignition switch, through
solid state device in IPM,tofuel
temperature sensor and on to fuel heater element.
The heater element operates on 12 volts, 300 watts at 0 °F (-18° C). As temperature increases, power requirements
decrease.
A minimum of 7 volts is required to operate the fuel heater. The resistance value of the heater element is less than
1 ohm (cold) and up to 1000 ohms warm.
TESTING
1. Disconnect electrical connector from thermostat.
Ambient temperature must be below the circuit close temperature. If necessary, induce this ambient temperature by
placing ice packs on thermostat to produce an effective ambient temperature below circuit close temperature.
Measure resistance across two pins. Operating range is 0.3 - 0.45 Ohms.
2. If resistance is out of range, remove thermostat and check resistance across terminal connections of heater. The
heater can be checked at room temperature. Operating range is 0.3 - 0.45 Ohms.
3. Replace heater if resistance is not within operating range.
4. If heater is within operating range, replace heater thermostat.

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 drive belt.
16. Connect both negative battery cables to both bat-
teries.
17. Check system for fuel or engine oil leaks.

LINES - FUEL
DESCRIPTION
Low-Pressure Lines Are:
the fuel supply line from fuel tank to fuel filter housing.
the fuel return line back to fuel tank.
the fuel drain (manifold) line at rear of cylinder head.
the fuel supply line from fuel filter to fuel injection pump.
the fuel injection pump return line.
High-Pressure Lines Are:
the fuel line from fuel injection pump to fuel rail.
the 6 fuel lines from fuel rail up to injector connector tubes
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.
OPERATION
High-Pressure Lines
CAUTION: The high-pressure fuel lines must be held securely in the brace. The lines cannot contact each
other or other components. Do not attempt to weld high-pressure fuel linesor to repair lines that are dam-
aged. If lines are ever kinked or bent, they must be replaced. Use only the recommended lines when
replacement of high-pressure fuel line is necessary.
High-pressure fuel lines deliver fuel (under pressure) of up to approximately 160,000 kPa (23,206 PSI) from the
injection pump to the fuel injectors. The lines expand and contract from the high-pressure fuel pulses generated
during the injection process. All high-pressure fuel lines are of the samelength and inside diameter. Correct high-
pressure fuel line usage and installation is critical to smooth engine operation.
WARNING: 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.
DIAGNOSIS AND TESTING
HIGH-PRESSURE FUEL LINE LEAKS
High-pressure fuel line leaks can cause starting problems and poor engineperformance.
WARNING: Due to extreme fuel pressures of up to 160,000 kpa (23,206 psi), use extreme caution when
inspecting for high-pressure fuel leaks. Do not get your hand or a finger near a suspected leak. 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.
Start the engine. Move the cardboard over the suspected high-pressure fuel line leak, and check for fuel spray onto
the cardboard. If line is leaking, retorque line while engine is shutdown.Replace damaged, restricted or leaking
high-pressure fuel lines with the correct replacement line.
CAUTION: The high-pressure fuel lines must be clamped securely in place inthe brace. The lines cannot
contact each other or other components. Do not attempt to weld high-pressure fuel lines or to repair lines
that are damaged. Only use the recommended lines when replacement of high-pressure fuel line is neces-
sary.

5. Install engine lifting bracket (1) and bolt. Torque nut
to 77 Nꞏm (56 ft. lbs.).
6. Tighten fuel lines at fuel rail. Torque nut to 37 Nꞏm
(27 ft. lbs.).
7. Tighten clamp support to intake manifold cover.
Torque nut to 24 Nꞏm (18 ft. lbs.).
8. If fuel line at either No. 1 or No. 2 cylinder has
been replaced, install intake manifold air heater
elements to top of intake manifold. Refer to Intake
Air Heater Removal / Installation for procedures.
9. If fuel line at No. 6 cylinder has been replaced, tilt
metal bracket (shield) upward and tighten 2 bolts at
rear of cylinder head. Torque nut to 43Nꞏm (32 ft.
lbs.).
10. Connect both negative battery cables to both bat-
teries.
11. Prime fuel system. Refer to Fuel System Priming.
12. Check lines/fittings for leaks.