2006 DODGE RAM SRT-10 sensor

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:

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.

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 DELIVERY/FUEL FILTER / WATER SEPA-
RATOR - REMOVAL).

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.

SENSOR - FUEL LEVEL SENDING UNIT
DESCRIPTION
The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit
consists of a float, an arm, and a variable resistor track (card). The fuel transfer (lift) pump is also attached to the
fuel pump module.
OPERATION
For Fuel Gauge Operation:A constant input voltage source of about 12 volts (battery voltage) is supplied to the
resistor track on the fuel gauge sending unit. This is fed directly from theEngine Control Module (ECM).NOTE: For
diagnostic purposes, this 12V power source can only be verified with the circuit opened (fuel tank module
electrical connector unplugged). With the connectors plugged, output voltages will vary from about .6 volts
at FULL, to about 7.0 volts at EMPTY.The resistor track is used to vary the voltage (resistance) depending on fuel
tank float level. As fuel level increases, the float and arm move up, which decreases voltage. As fuel level
decreases, the float and arm move down, which increases voltage. The varied voltage signal is returned back to the
ECM through the sensor return circuit.
Both of the electrical circuits between the fuel gauge sending unit and theECM are hard-wired (not multi-plexed).
After the voltage signal is sent from the resistor track, and back to the ECM, the ECM will interpret the resistance
(voltage) data and send a message across the multi-plex bus circuits to theinstrument panel cluster. Here it is
translated into the appropriate fuel gauge level reading. Refer to Instrument Panel for additional information.
REMOVAL
REMOVAL/INSTALLATION
For diesel removal and installation procedures, refer to the gas section of Fuel System/Fuel Delivery. See Fuel
Level Sending Unit/Sensor Removal/Installation.

SENSOR - FUEL PRESSURE
DESCRIPTION
The fuel pressure sensor is mounted vertically near the top/center of the fuel rail.
OPERATION
The fuel pressure sensor monitors actual high-pressure within the fuel rail. An output signal from this sensor (relat-
ing to fuel pressure) is sent to the Engine Control Module (ECM).
REMOVAL
The fuel pressure sensor (4) is mounted vertically
near the top/center of the fuel rail.
1. Disconnect electrical connector (1) at sensor.
2. Remove sensor from fuel rail.
3. Inspect sensor sealing surface.
INSTALLATION
1. Inspect fuel pressure sensor sealing surface.
2. Lubricate sensor threads with clean diesel fuel.
3. Install sensor (4) into fuel rail.
4. To prevent leaks, sensormustbe tightened to 70
Nꞏm (52 ft. lbs.).
5. Connect electrical connector to sensor.
6. Start engine and check for fuel leaks.

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.