DODGE RAM SRT-10 2006 Service Repair Manual

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.

1. Disconnect both negative battery cables at both
batteries. Cover and isolate ends of both cables.
2. Remove intake manifold air intake tube (above
injection pump) and its rubber connector hose (2).
3. Remove accessory drive belt.
4. Thoroughly clean the rear of injection pump, and
attachment points for its 3 fuel lines. Also clean the
opposite ends of these same 3 lines at their attach-
ment points.

5. Disconnect Fuel Control Actuator (FCA) electrical
connector (3) at rear of injection pump.
CAUTION: Whenever a fuel line fitting is con-
nected to a secondary fitting, always use a
back-upwrenchonthesecondaryfitting.Donot
allow the secondary fitting to rotate.
6. Remove fuel line (injection pump-to-fuel pressure
limiting valve).
7. Remove fuel line (injection pump-to-fuel rail). Use
back-up wrench on fitting at fuel pump.
8. Remove fuel line (injection pump-to-fuel filter
housing).
9. Remove fuel pump drive gear access cover with a
3/8” drive ratchet. Access cover (2) is threaded to
timing gear cover.
10. Remove fuel pump drive gear mounting nut and
washer.

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.

1. Inspect pump mounting surfaces at pump and
mounting flange and pilot bore for nicks, cuts or
damage. Inspect O-ring surfaces for nicks, cuts or
damage.
2. Clean injection pump mounting flange and pilot
bore at gear housing. Also clean front of injection
pump.
3. Install new rubber O-ring (square) into machined
groove at pump mounting area.
4. Apply clean engine oilto injection pump O-ring
and pilot bore only.
The machined tapers on both injection pump shaft
and injection pump gear must be absolutely dry, clean and free of any dirt oroil film. This will ensure
proper gear-to-shaft tightening.
5. Clean pump gear and pump shaft at machined tapers with an evaporative type cleaner such as brake cleaner.
6. Position injection pump to mounting flange on gear housing while aligning injection pump shaft through back of
injection pump gear.
7. After pump is positioned flat to mounting flange,
install 3 pump mounting nuts (3) and tightenfinger
tight only.Do not attempt a final tightening at this
time.Do not attempt to tighten (pull) pump to
gear housing using mounting nuts. Damage to
pump or gear housing may occur. The pump
must be positioned flat to its mounting flange
before attempting to tighten 3 mounting nuts.
8. To prevent damage or cracking of components,
install and tighten nuts in the following sequence:
a. Install injection pump shaft washer and nut to
pump shaft. Tighten nutfinger tight only.
b. Do preliminary (light) tightening of injection
pump shaft nut.
c. Tighten 3 injection pump mounting nuts to 24
Nꞏm (18 ft. lbs.).
d. Do a final tightening of pump shaft nut to 105
Nꞏm (77 ft. lbs.).

9. Install drive gear access cover (2) using a 3/8”
drive ratchet. Access cover is threaded to timing
gear cover. Tighten to 8 Nꞏm (71 in. lbs.) torque.
10. Install fuel return line (injection pump-to-fuel filter).
Tighten banjo bolts (1) to 24 Nꞏm (18 ft. lbs.)
torque.
11. Install fuel line (injection pump-to-fuel rail).
a. Tighten fitting at fuel pump to 37 Nꞏm (27 ft.
lbs.) torque. Use a back-up wrench.
b. Tighten fitting at fuel rail to 37 Nꞏm (27 ft. lbs.)
torque.
12. Install fuel line (injection pump-to-fuel filter hous-
ing). Tighten to 24 Nꞏm (18 ft. lbs.) torque.

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.