2006 DODGE RAM SRT-10 fuel filter

Possible Causes
RESTRICTED FUEL SUPPLY LINE
FUEL PUMP INLET STRAINER PLUGGED
(A109) FUEL PUMP RELAY OUTPUT CIRCUIT OPEN
FUEL PUMP RELAY
FUEL PUMP
Diagnostic Test
1.FUEL PUMP OPERATION
Ignition on, engine not running.
With a scan tool, actuate the Fuel System test.
NOTE: It may be necessary to use a mechanics stethoscope in the next step.
Listen for fuel pump operation at the fuel tank.
Does the Fuel Pump operate?
Ye s>>
Go To 2
No>>
Go To 5
CAUTION: Stop All Actuations.
2.FUEL PRESSURE
Turn the ignition off.
WARNING: The fuel system is under a constant pressure (even with the engineoff). Before testing or ser-
vicing any fuel system hose, fitting or line, the fuel system pressure mustbe released. Failure to follow
these instructions can result in personal injury or death.
Install a fuel pressure gauge at the engine.
Ignition on, engine not running.
With the scan tool, actuate the ASD FuelSystem test and observe the fuel pressure gauge.
NOTE: NOTE: Fuel pressure specification is 407 KPa +/- 34 KPa (59 psi +/- 5 psi).
Choose a conclusion that best matches your fuel pressure reading.
Below Specification
Go To 3
Within Specification
Te s t C o m p l e t e .
Above Specification
Replace the fuel filter/fuel pressure regulator.
Perform the POWERTRAIN VERIFICATION TEST. (Refer to 9 - ENGINE - STANDARD PROCEDURE)
CAUTION: Stop All Actuations.
3.RESTRICTED FUEL SUPPLY LINE
Turn the ignition off.
WARNING: The fuel system is under a constant pressure even with the engine off. Before testing or ser-
vicing any fuel system hose, fitting or line, the fuel system pressure mustbe released.
Raise vehicle on hoist, and disconnect the fuel pressure line at the fuel pump module.
Install special tool #6539 (5/16
) or #6631(3/8) fuel line adapter and the fuel pressure gauge between the fuel sup-
ply line and the fuel pump module.
Ignition on, engine not running.
With the scan tool, actuate the ASD FuelSystem test and observe the fuel pressure gauge.

3.INJECTION SYSTEM
Perform “*INJECTOR RETURN FLOW TEST”. If okay continue.
Check for correct injectors and injector shims.
Visuslly inspect injector wire nuts and pass through connectors for damageorcorrosion.
Is vehicle repaired?
Ye s>>
Repair complete.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
No>>
Go To 4
4.FUEL RETURN
Check for kinked or restricted fuel return lines.
Check fuel tank venting.
Is vehicle repaired?
Ye s>>
Repair complete.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
No>>
Go To 5
5.INTAKE SYSTEM
Check for inlet restriction, inspect air filter for excessive dirt/debris. Verify air intake lines are not kinked or restricted.
Check for air system leaks. Perform “*INTAKE AIR SYSTEM PRESSURE TEST - DIESEL”.
Inspect Turbocharger for wheel clearance and proper wastegate operation.
Is vehicle repaired?
Ye s>>
Repair complete.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
No>>
Go To 6
6.OTHER VEHICLE SYSTEMS
Verify proper operation of the Transmission Clutch.
Verify proper operation of the Transmission.
Verify proper operation of the Vehicle brakes (check for dragging).
Verify proper operation of the Cooling fan operation cycle time.
Verify proper operation of the Engine driven accessories.
Verify proper operation of the Accelerator pedal (restricted or out of calibration).
Is vehicle repaired?
Ye s>>
Repair complete.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
No>>
Go To 7

1.
1. Using the Scan tool, check for DTCs. Troubleshoot any active DTCs beforeperforming this test.
2. Disconnect the wiring harness from the lift pump at the fuel tank module connector and inspect the pins for
damage. Fix or replace any damaged component.
3. Connect a voltmeter between the fuel lift pump supply and return pins at the fuel tank module connector.
4. Turn the ignition to the on position. Use the Scan tool to actuate the fuellift pump, record the voltage on the
voltmeter.
5. If the voltage is greater than 11.5 volts, go to step 14. If the voltage is lessthan11.5volts,gotostep6
6. Using a voltmeter, measure the battery voltage to determine that the voltage is greater than 11.5 volts. If the
voltage is greater than 11.5 volts, go to step 7. If the voltage is not greater than 11.5 volts, troubleshoot for low
battery voltage.
7. Remove the fuel lift pump relay from the PDC. Use a voltmeter to measure the voltage at the fuel lift pump relay
voltage supply pin in the PDC. If the voltage is greater than 11.5 volts, go to step 8. If the voltage is not greater than
11.5 volts, fix or replace the harness.
8. Remove the fuel lift pump relay from the PDC. Install a spare relay in place of the fuel lift pump relay. Using the
Scan tool, actuate the fuel lift pump. Use a voltmeter to measure the voltage between the fuel lift pump supply and
return pins at the fuel tank module connector while the fuel lift pump is actuated. If the voltage is greater than 11.5
volts, replace the fuel lift pump relay. If the voltage is not greater than 11.5volts,gotostep9.
9. Disconnect the wiring harness from the fuel tank module. Remove the liftpump relay from the PDC. Using an
Ohmmeter, measure the resistance of the fuel lift pump power supply wire between the PDC relay output pin and
the fuel tank module connector. If the resistance is less than 10 ohms, go tostep 10. If it is greater than 10 ohms,
fix or replace the harness.
10. Disconnect the wiring harness from the fuel tank module. Remove the fuel lift pump relay from the PDC. Using
a voltmeter, measure the voltage between battery negative and the fuel lift pump power supply wire at the fuel
module connector. If the voltage is less than 1 volt, go to step 11. If the voltage is greater than 1 volt, fix or replace
the harness.
11. Disconnect the wiring harness from the fuel tank module. Remove the fuel lift pump relay from the PDC. Using
an ohmmeter, measure the resistance between battery negative and the fuellift pump power supply wire at the fuel
module connector. If the resistance is less than 10 ohms, fix or replace theharness. If the resistance is greater than
10 ohms, go to step 12.
12. Disconnect the wiring harness from the fuel tank module. Using an Ohmmeter, measure the resistance of the
fuel lift pump ground wire between the fuel tank module connector and battery negative. If the resistance is less
than 10 ohms, go to step 13. If the resistance is greater than 10 ohms, fix or replace the harness.
13. Disconnect the wiring harness from the fuel tank module. Using a voltmeter, measure the voltage between the
fuel lift pump ground wire and battery negative. If the voltage is less than1 volt, go to step 14. If the voltage is
greater than 1 volt, fix or replace the harness.
14. Reconnect the lift pump connector.
FLOW TEST.
1. Remove the fuel pump supply banjo fitting from the fuel injection pump.
2. Install Miller Tool #9014 fuel system test fitting into the fuel injection pump.
3. Connect one end of a section of fuel hose to the test fitting.
4. Put the other end of the fuel hose into an empty fuel container.
5. Use the scan tool to actuate the fuel lift pump.
6. While the lift pump is running, move the fuel hose from the fuel canister into a 1000ml graduated cylinder for 10
seconds.
7. Read and record the amount of fuel in the graduated cylinder after 10 seconds.
8. If you have more than 430ml in the graduated cylinder after 10 seconds, the test has successfully passed.
9. If you have less than 430ml of fuel in the graduated cylinder, inspect thefuel supply line from the fuel tank to the
fuel filter housing and the fuel supply line between the fuel filter housing and the high pressure fuel pump for signs
of damage, replace as necessary. If no damage is found, replace the fuel filter and retest.
10.Verify the Screened Banjo Bolt at the outlet of the fuel filter is free ofdebris. If debris is found, rinse screen with
water, blow dry and reinstall. Retest vehicle. If flow meets specification then trace back the source of debris, if flow
is still below spec repair damaged component.

*FUEL PUMP RETURN FLOW TEST
Possible Causes
EXCESSIVE FUEL PUMP RETURN FLOW
Diagnostic Test
1.FUEL PUMP RETURN FLOW TEST
Using the scan tool, idle the engine and measure the rail pressure and determine if the rail pressure is excessive
(above 185,00 kpa/26,831 psi), if it is, troubleshoot for excessive rail pressure first.
Remove the banjo bolt from the pressure-limiting valve on the fuel rail.
Install fuel system test fitting #9013 into the pressure-limiting valve.
Attach one end of a fuel hose to the fuel fitting and put the other end of the fuel hose into a container
Perform the tests listed below to determine if the pressure-limiting valve is leaking.
a. Operate the engine at idle and watch for fuel flow into the fuel container.
b. Operate the engine at idle and actuate the high pressure safety valve test with the scan tool. Watch for fuel flow
into the fuel container.
If fuel flows into the fuel container, replace the pressure-limiting valve. If fuel does not leak from the pressure-limiting
valve, the test is complete.
NOTE: do not drive the vehicle with any portion of this test kit installed
Operate the engine until the engine is at operating temperature.
Remove the banjo connector from the fuel drain tube at the rear of the fuel filter housing
Install fuel system test fitting #9012 in place of the banjo connector.
Install a piece of fuel line onto the test fitting and put the open end into the graduated cylinder.
Start the engine and let it idle for one minute.
Measure the amount of fuel in the graduated cylinder.
If the flow is less than 1000-ml/minute at idle, the test has successfully passed.
If the flow is greater than 1000 ml/minute at idle, replace the fuel injection pump.
Retest to confirm repair.
View Repair
Repair
Te s t C o m p l e t e .
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)

*INJECTOR RETURN FLOW TEST
Diagnostic Test
1.* INJECTOR RETURN FLOW TEST
1. Operate the engine until the engine is at operating temperature.
2. Remove the banjo connector from the fuel drain tube at the rear of the fuelfilter housing.
3. Install fuel system test fitting (9012) in place of the banjo connector.
4. Remove the vehicle fuel return line from the engine fuel drain tube. Route this hose into a container to catch bled
fuel.
5. Install a piece of fuel line onto the test fitting and into a fuel container or into the fuel tank.
6. Install one end of a test hose onto the fuel drain tube. Place the other endof the test hose into a graduated
cylinder.
7. Start the engine and let it idle for one minute.
8. Measure the amount of fuel in the graduated cylinder.
9. If the flow is less than 180-ml/minute, the test has successfully passed.
10. If the flow is greater than 180 ml/minute, shut off the engine and removeall of the fuel injector supply lines. Re
torque all of the high-pressure connector nuts. Install all of the fuel injector supply lines.
11. Start the engine and idle for one minute. Measure the amount of fuel in the graduated cylinder.
12. If the flow is less than 180ml/minute, the condition has been fixed.
13. If the flow is greater than 180 ml/minute after step 12, shut off the engine and remove the #1 fuel injector supply
line. Re torque the high-pressure connector nut. Cap the #1 fuel port usingtool #9011 on the fuel rail and the #1
high pressure connector.
14. Start the engine. Measure the amount of fuel in the graduated cylinder.
15. If the amount of fuel is less than 180 ml/minute, shut off the engine and remove the #1 high pressure connector
and the #1 fuel injector. Inspect for damage, repair/replace as necessary.
16. If the amount of fuel is not less than 180-ml/minute, repeat steps 14-16for cylinders 2-6.
17. Install all high-pressure connectors, fuel injectors, and fuel injector supply lines. Repeat steps 1-8 to confirm
repair.
SPECIFICATION:Less than 180 ml/minute total fuel return flow
Repair
Te s t C o m p l e t e .
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)

Theory of Operation
The fuel feedback system will maintain a stoiciometric fuel/air mixture,14.7:1, by modifying the injector pulsewidth
according to the oxygen content of the exhaust gas. The PCM makes short termand long term fuel corrections to
maintain stoiciometric fuel/air ratio for best catalytic converter efficiency. Short term fuel correction is based on
upstream O2 sensor output and is designed for quick engine response. The long term fuel correction compensated
for variations in the engine specifications, sensor tolerances and component aging and is designed to correct rich
and lean conditions over a longer period of time.
When Monitored:
With the engine running in closed loop mode, the ambient/battery temperature above 20 deg. F and altitude
below 8500 ft.
Set Condition:
If the PCM multiplies short term compensation by long term adaptive and a certain percentage is exceeded for
two trips, a freeze frame is stored, the MIL illuminates and a trouble code is stored. Two Trip Fault. Three good
trips to turn off the MIL
Possible Causes
FUEL PRESSURE OUT OF SPECS
RESTRICTED FUEL SUPPLY LINE
FUEL PUMP INLET STRAINER PLUGGED
FUEL PUMP MODULE
O2 SENSOR
(K41) O2 SENSOR 1/1 SIGNAL CIRCUIT SHORTED TO GROUND
O2 SENSOR 1/1 HEATER OPERATION
TP SENSOR
MAP SENSOR
ECT SENSOR
ENGINE MECHANICAL CONDITION
FUEL FILTER/PRESSURE REGULATOR
PCM
Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING).
Diagnostic Test
1.GOOD TRIP EQUAL TO ZERO
NOTE: Check for contaminates that may have damaged the O2 Sensor: contaminated fuel, unapproved sil-
icone, oil and coolant.
Ignition on, engine not running.
With the scan tool, read DTCs and record the related Freeze Frame data.
Is the Good Trip Counter displayed and equal to zero?
Ye s>>
Go To 2
No>>
Refer to the INTERMITTENT CONDITION Diagnostic Procedure.
Perform the POWERTRAIN VERIFICATION TEST. (Refer to 9 - ENGINE - STANDARD PROCEDURE)

2.CHECKING FUEL PRESSURE
WARNING: The fuel system is under a constant pressure (even with the engineoff). Before testing or ser-
vicing any fuel system hose, fitting or line, the fuel system pressure mustbe released.
Install a fuel pressure gauge.
Ignition on, engine not running.
With the scan tool, actuate the ASD FuelSystem test and observe the fuel pressure gauge.
NOTE: Fuel pressure specification is 379 KPa +/- 14 KPa (55 psi +/- 2 psi).
Turn the ignition off.
Choose a conclusion that best matches your fuel pressure reading.
Below Specification
Go To 3
Within Specification
Go To 6
Above Specification
Replace the fuel filter/pressure regulator.
Perform the POWERTRAIN VERIFICATION TEST. (Refer to 9 - ENGINE - STANDARD PROCEDURE)
CAUTION: Stop All Actuations.
3.RESTRICTED FUEL SUPPLY LINE
Turn the ignition off.
WARNING: The fuel system is under a constant pressure (even with the engineoff). Before testing or ser-
vicing any fuel system hose, fitting or line, the fuel system pressure mustbe released.
Raise vehicle on hoist, and disconnect the fuel pressure line at the fuel pump module.
Install special 5/16 fuel line adapter tool #6539 or #6631 for 3/8 fuel lineadapter, between the disconnected fuel line
and the fuel pump module.
Attach a fuel pressure test gauge to the T fitting on tool #6539 or #6631.
Ignition on, engine not running.
With the scan tool, actuate the ASD FuelSystem test and observe the fuel pressure gauge.
NOTE: Fuel pressure specification is 379 KPa +/- 14 KPa (55 psi +/- 2 psi).
CAUTION: Stop All Actuations.
Is the fuel pressure within specification?
Ye s>>
Repair or replace fuel supply line as necessary.
Perform the POWERTRAIN VERIFICATION TEST. (Refer to 9 - ENGINE - STANDARD PROCEDURE)
No>>
Go To 4
4.FUEL PUMP INLET STRAINER
Turn the ignition off.
WARNING: The fuel system is under a constant pressure (even with the engineoff). Before testing or ser-
vicing any fuel system hose, fitting or line, the fuel system pressure mustbe released.
Remove the Fuel Pump Module and inspect the Fuel Inlet Strainer.
Is the Fuel Inlet Strainer plugged?
Ye s>>
Replace the Fuel Pump Inlet Strainer.
Perform the POWERTRAIN VERIFICATION TEST. (Refer to 9 - ENGINE - STANDARD PROCEDURE)
No>>
Go To 5

Theory of Operation
The fuel feedback system will maintain a stoiciometric fuel/air mixture,14.7:1, by modifying the injector pulsewidth
according to the oxygen content of the exhaust gas. The PCM makes short termand long term fuel corrections to
maintain stoiciometric fuel/air ratio for best catalytic converter efficiency. Short term fuel correction is based on
upstream O2 sensor output and is designed for quick engine response. The long term fuel correction compensated
for variations in the engine specifications, sensor tolerances and component aging and is designed to correct rich
and lean conditions over a longer period of time.
When Monitored:
With the engine running in closed loop mode, the ambient/battery temperature above 20 deg. F and altitude
below 8500 ft.
Set Condition:
If the PCM multiplies short term compensation by long term adaptive and a purge fuel multiplier and the result
is below a certain value for 30 seconds over two trips, a freeze frame is stored, the MIL illuminates and a
trouble code is stored. Two Trip Fault. Three good trips to turn off the MIL.
Possible Causes
O2 SENSOR
(K41) O2 SENSOR 1/1 SIGNAL CIRCUIT OPEN
(K41) O2 SENSOR 1/1 SIGNAL CIRCUIT SHORTED TO VOLTAGE
1/1 O2 SENSOR HEATER OPERATION
EVAP SYSTEM OPERATION
TP SENSOR VOLTAGE GREATER THAN 0.92 OF A VOLT WITH THROTTLE CLOSED
TP SENSOR
FUEL FILTER/PRESSURE REGULATOR
MAP SENSOR
ECT SENSOR
ENGINE MECHANICAL CONDITION
PCM
Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING).
Diagnostic Test
1.GOOD TRIP EQUAL TO ZERO
NOTE: Check for contaminates that may have damaged the O2 Sensor: contaminated fuel, unapproved sil-
icone, oil and coolant.
Ignition on, engine not running.
With the scan tool, read DTCs and record the related Freeze Frame data.
NOTE: Any O2 Sensor, TPS, ECT, MAP, or EVAP DTCs must be repaired before continuing.
Is the Good Trip Counter displayed and equal to zero?
Ye s>>
Go To 2
No>>
Refer to the INTERMITTENT CONDITIONSymptom (Diagnostic Procedure).
Perform the POWERTRAIN VERIFICATION TEST. (Refer to 9 - ENGINE - STANDARD PROCEDURE)