engine DODGE RAM SRT-10 2006 Service Repair Manual

INSTALLATION
1. If fuel tank is to be replaced, install fuel tank mod-
ule into tank. (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY/FUEL TANK MODULE - REMOVAL).
2. Position fuel tank (1) to hydraulic jack.
3. Raise tank until positioned near body.
4. Connect fuel tank module electrical connector at
top of tank.
5. Connect fuel supply and return lines to tank mod-
ule.
6. Continue raising tank until positioned snug to body.
7. Install and position both tank support straps (4).
Install 2 fuel tank strap nuts and tighten to 41 Nꞏm
(30 ft. lbs.).Tighten rear strap nut first.
8. Remove hydraulic jack.
9. Connect rubber fill hose to fuel fill tube and tighten
clamp.
10. Install tire / wheel (if necessary).
11. Lower vehicle.
12. Fill fuel tank with fuel.
13. Start engine and check for fuel leaks near top of module.

PUMP - FUEL TRANSFER
DESCRIPTION
The fuel transfer pump (fuel lift pump) is part of the fuel pump module. The fuel pump module is located in the fuel
tank. The 12–volt electric pump is operated and controlled by the Engine Control Module (ECM). The ECM controls
a relay in the Intelligent Power Module(IPM) for transfer pump operation.
OPERATION
The purpose of the fuel transfer pump is to supply (transfer) a low-pressure fuel source:fromthe fuel tank,through
the fuel filter/water separator andtothe fuel injection pump. Here, the low-pressure is raised to a high-pressure by
the fuel injection pump for operation of the high-pressure fuel injectors. Check valves within the pump, control direc-
tion of fuel flow and prevent fuel bleed-back during engine shut down.
Maximum current flow to the pump is 5 amperes.
With the engine running, the pump has a 100 percent duty-cycle.
The transfer pump is self-priming: When the key is first turned on (withoutcranking engine), the pump will operate
for approximately 2 seconds and then shut off (Note: When ambient temperatures are cold enough to cause the
intake air heaters to operate, the fuel lift pump will operate during the entire intake air pre-heat cycle). The pump will
also operate for up to 25 seconds after the starter is engaged, and then disengaged and the engine is not running.
The pump shuts off immediately if the key is on and the engine stops running.
The fuel volume of the transfer pump will always provide more fuel than the fuel injection pump requires. Excess
fuel is returned from the injection pump through an overflow valve, and then back to the fuel tank.
REMOVAL
The fuel transfer pump (fuel lift pump) is a part of the fuel tank module. It is not serviced separately. Refer to Fuel
Tank Module Removal or Installation for procedures (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL TANK
MODULE - REMOVAL).
INSTALLATION
The fuel transfer pump (fuel lift pump) is a part of the fuel tank module. It is not serviced separately (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL TANK MODULE - INSTALLATION).

SENSOR-WATER IN FUEL
DESCRIPTION
The Water-In-Fuel (WIF) sensor (5) is located on the
side of the fuel filter/water separator canister.
OPERATION
The sensor sends an input to the Engine Control Module (ECM) when it senses water in the fuel filter/water sep-
arator. As the water level in the filter/separator increases, the resistance across the WIF sensor decreases. This
decreaseinresistanceissentasasignaltotheECMandcomparedtoahighwater standard value. Once the value
reaches 30 to 40 kilohms, the ECM will activate the water-in-fuel warning lamp through CCD bus circuits. This all
takes place when the ignition key is initially put in the ON position. The ECM continues to monitor the input while
the engine is running.
REMOVAL
The Water-In-Fuel (WIF) sensor is located at the side of fuel filter/waterseparator canister. (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY/FUEL TANK MODULE - INSTALLATION).

SENSOR-ACCELERATOR PEDAL POSITION
DESCRIPTION
The Accelerator Pedal Position Sensor (APPS) (1) is
located inside the vehicle.It is attached to the accel-
erator pedal assembly (3).
OPERATION
The Accelerator Pedal Position Sensor (APPS) provides the Engine ControlModule (ECM) with two DC voltage
signals which change as the position of the accelerator pedal changes. Oneof the DC voltage signals will be half
the voltage of the other signal.
REMOVAL
CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the
accelerator pedal assembly. The APPS is replaced as an assembly along withthe pedal. If sensor is
removed from pedal, its electronic calibration may be destroyed.
1. Disconnect 6–way electrical connector at top of
APPS (2).
2. Remove APPS lower mounting bolt (4) and two
mounting nuts.
3. Remove pedal and APPS assembly from vehicle.

SENSOR-CAMSHAFT POSITION
DESCRIPTION
The Camshaft Position Sensor (CMP) on the 5.9L diesel engine is located below the fuel injection pump. It is bolted
to the back of the timing gear housing.
OPERATION
The diesel Camshaft Position Sensor (CMP) contains
a hall effect device. A rotating target wheel (tone-
wheel) for the CMP is located on the camshaft gear.
This hall effect device detects holes located on the
back side of the camshaft gear. As the camshaft gear
rotates, the holes pass the tip of the CMP.
When the leading edge of the hole passes the tip of
the CMP, the following occurs: The interruption of
magnetic field causes the voltage to switch high
resulting in a signal of approximately 5 volts.
When the trailing edge of the hole passes the tip of
the CMP, the following occurs: The change of the
magnetic field causes the signal voltage to switch low
to 0 volts.
The CMP (1) provides a signal to the Engine Control
Module (ECM) at all times when the engine is running.
TheECMusestheCMPinformationprimarilyon
engine start-up. Once the engine is running, the ECM
uses the CMP as a backup sensor for engine speed.
The Crankshaft Position Sensor (CKP) is the primary
engine speed indicator for the engine after the engine
is running.
REMOVAL
The Camshaft Position Sensor (CMP) on the 5.9L die-
sel engine is located (1) below the fuel injection pump.
It is bolted to the back of the timing gear housing (7).
1. Disconnect electrical connector at CMP sensor.
2. Remove sensor mounting bolt (6).
3. Carefully twist and pull the sensor from timing gear
housing.
4. Check condition of sensor O-ring.

INSTALLATION
1. Clean out machined hole in back of timing gear
housing.
2. Apply a small amount of engine oil to sensor O-ring
and sensor hole.
3. Install sensor into timing gear housing with a slight
rocking action. Do not twist sensor into position as
damagetoO-ringmayresult.
CAUTION: Before tightening sensor mounting bolt,
be sure sensor is completely flush to back of tim-
ing gear housing (cover). Remove (cover) if sensor
is not flush, damage to sensor mounting tang may
result.
4. Install mounting bolt and tighten. Torque to 9 Nꞏm
(80 in. lbs.).
5. Connect electrical connector (5) to sensor.

SENSOR-CRANKSHAFT POSITION
DESCRIPTION
The Crankshaft Position Sensor (CKP) on the diesel engine is attached at thefront/leftsideoftheenginenextto
the engine harmonic balancer (crankshaft damper).
OPERATION
The Crankshaft Position Sensor (CKP) (5) is the pri-
mary engine speed indicator for the engine after the
engine is running.
The CKP contains a hall effect device. A rotating,
notched target wheel (tonewheel) for the CKP is
located behind the engine harmonic balancer (2). This
hall effect device detects notches located on the tone-
wheel. As the tonewheel rotates, the notches pass the
tip of the CKP.
When the leading edge of the tonewheel notch passes
the tip of the CKP, the following occurs: The interrup-
tion of magnetic field causes the voltage to switch
high resulting in a signal of approximately 5 volts.
When the trailing edge of the tonewheel notch passes
the tip of the CKP, the following occurs: The change of
the magnetic field causes the signal voltage to switch
lowto0volts.
The Camshaft Position Sensor (CMP) also provides a
signal to the Engine Control Module (ECM) at all times
when the engine is running. The ECM uses this CMP
information primarily on engine start-up. Once the
engine is running, the ECM uses the CMP as a
backup sensor for engine speed.

REMOVAL
1. Raise and support vehicle
2. Disconnect electrical connector (4) at CKP sensor.
3. Remove 1 sensor mounting bolt (3).
4. Remove CKP sensor.
INSTALLATION
1. Position and install CKP sensor (5) to engine.
2. Install 1 sensor mounting bolt and tighten to 9 Nꞏm
(80 in. lbs.) torque.
3. Install electrical connector (4) to CKP sensor.

INJECTOR - FUEL
DESCRIPTION
Six individual, solenoid actuated high-pressure fuel
injectors are used. The injectors are vertically mounted
into a bored hole in the top of the cylinder head. This
bored hole is located between the intake/exhaust
valves.
High-pressure connectors, mounted into the side of the cylinder head, connect each fuel injector to each high-pres-
sure fuel line. The injector part number is laser-burned onto the injector. Failure to replace with the proper injector
will cause severe engine damage.

4. Remove valve cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL).
5. Remove all 12 fuel injector wire harness nuts (1) securing integrated wiring harness to all 6 fuel injectors.
6. Remove all 12 fuel injector wire harness nuts (1)
securing integrated wiring harness to all 6 fuel
injectors.
7. An integrated fuel injector wire harness / valve
cover gasket (2) is used. After all 12 nuts (1) have
been removed, remove this integrated gasket.
Before removing gasket, disconnect engine wiring
harness at both electrical connectors (3).
8. Remove necessary high pressure fuel line connecting the necessary fuelinjector rail to high pressure connector.
Refer to Fuel Line Removal for procedures.
9. A connector retainer (nut) is used on each connector tube. Remove this nut(s) by unthreading from cylinder
head.