ESP DODGE RAM SRT-10 2006 Service Repair Manual

RECOVERY/RECYCLING/EVACUATION/CHARGING HOSE– The center manifold hose (Yellow, or White, with
Black stripe) (3) is used to recover, evacuate, and charge the refrigerantsystem. When the low or high pressure
valves on the manifold gauge set are opened, the refrigerant in the system will escape through this hose.
HIGH PRESSURE GAUGE HOSE– The high pressure hose (Red with Black stripe) (4) attaches to the high side
service port. This service port is located on the A/C discharge line. On this model, an A/C pressure transducer is
installed on the high side service port. A/C high-side pressures can be read using a scan tool. Refer to 9 - Engine
Electrical Diagnostics for more information.
LOW PRESSURE GAUGE HOSE– The low pressure hose (Blue with Black stripe) (5) attaches to the low side
service port. This service port is located either on the top of the A/C accumulator or on the A/C suction line near the
accumulator, depending on engine application.
REFRIGERANT SYSTEM RECOVERY
WARNING: Refer to the applicable warnings and cautions for this system before performing the following
operation (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - WARNINGS) and (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - CAUTIONS). Failure to follow the warnings and cautions could result
in possible personal injury or death.
An R-134a refrigerant recovery/recycling/charging sta-
tion (1) that meets SAE standard J2210 must be used
to recover the refrigerant from the R-134a refrigerant
system. Refer to the operating instructions supplied by
the equipment manufacturer for the proper care and
use of this equipment.
REFRIGERANT SYSTEM EVACUATE
NOTE: Special effort must be used to prevent moisture from entering the A/Csystem oil. Moisture in the oil
is very difficult to remove and will cause a reliability problem with the compressor.
If an A/C compressor designed to use R-134a refrigerant is left open to the atmosphere for an extended period of
time. It is recommended that the refrigerant oil be drained and replaced with new oil or a new A/C compressor be
used. This will eliminate the possibility of contaminating the refrigerant system.
If the refrigerant system has been open to the atmosphere, it must be evacuated before the system can be filled.
Moisture and air mixed with the refrigerant will raise the compressor headpressure above acceptable operating
levels. This will reduce the performance of the A/C system and damage the A/C compressor. Moisture will boil at
near room temperature when exposed to vacuum. To evacuate the refrigerantsystem:
NOTE: When connecting the service equipment coupling to the line fitting,verify that the valve of the cou-
pling is fully closed. This will reduce the amount of effort required to make the connection.
1. Recover the refrigerant system (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PRO-
CEDURE - REFRIGERANT SYSTEM RECOVERY).
2. Connect a suitable charging station, refrigerant recovery machine or amanifold gauge set with vacuum pump
and refrigerant recovery equipment (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD
PROCEDURE - REFRIGERANT SYSTEM SERVICE EQUIPMENT).
3. Open the suction and discharge valves and start the vacuum pump. The vacuum pump should run a minimum of
45minutespriortochargetoeliminateall moisture in system. When the suction gauge reads to the lowest

NOTE: Illustration shown with air seal removed for
clarity.
1. Position the A/C condenser (5) into the engine
compartment.
2. Install the four bolts (2, 4, 6 and 7) that secure the
A/C condenser to the charge air cooler. Tighten the
bolts to 10.5 Nꞏm (95 in. lbs.).
3. Remove the tape or plugs from the liquid line fitting
and condenser outlet port.
4. Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the liquid line fitting.
UseonlythespecifiedO-ringasitismadeofa
special material for the R-134a system. Use only
refrigerant oil of the type recommended for the A/C
compressor in the vehicle.
5. Connect the A/C discharge line (1) and the A/C liq-
uid line (3) onto the A/C condenser (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/
LINE-A/C DISCHARGE - INSTALLATION) and
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/LINE-A/C LIQUID - INSTALLATION).
6. Position the air seal over the front passenger side
of the A/C condenser and install the air seal retain-
ers.
7. Reconnect the negative battery cable.
8. Evacuate the refrigerant system (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PRO-
CEDURE - REFRIGERANT SYSTEM EVACUATE).
9. Charge the refrigerant system (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PRO-
CEDURE - REFRIGERANT SYSTEM CHARGE).
8.3L ENGINE
NOTE: If the A/C condenser is being replaced, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrig-
erant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
NOTE: Be certain that each of the radiator and condenser air seals are reinstalled in their proper locations.
These air seals are required for the A/C and engine cooling systems to perform as designed.

FAN-A/C CONDENSER
DESCRIPTION
All models equipped with gasoline engines, except
SRT 8, use an electric cooling fan to help pull heat out
of the A/C system, especially during idle conditions.
Without a cooling fan, A/C high side pressures would
increase and A/C system performance would eventu-
ally deteriorate.
The A/C condenser fan consists of a plastic fan blade
assembly which is driven by a 12-volt direct current
(DC) motor (1) with an integral wire harness connector
(2). The A/C condenser fan is mounted within a plastic
shroud (3) behind the A/C condenser (4) located in the
left front of the engine compartment.
OPERATION
The A/C condenser fan used in gasoline engine equipped models (except SRT 8) is controlled by the powertrain
control module (PCM). When the A/C-heater control is set to any A/C position, it sends a request signal on the
CAN-B bus to the totally integrated power module (TIPM), which then transfers the request on the CAN-C Bus to
the PCM/ECM, which sends a signal on a dedicated hard-wired circuit to the totally integrated power module (TIPM)
to energize the internal A/C condenser fan high side driver. When energized, the A/C condenser fan high side driver
provides battery current to the condenser fan motor.
The A/C condenser fan control system isdiagnosed using a scan tool (Refer to 24 - HVAC Electrical Diagnostics for
more information).
The components of the A/C condenser fan cannot be repaired and, if faulty ordamaged, they must be replaced as
an assembly.
REMOVAL
WARNING: Refer to the applicable warnings and cautions for this system before performing the following
operation (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - WARNINGS) and (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - CAUTIONS). Failure to follow the warnings and cautions could result
in possible personal injury or death.
1. Recover the refrigerant from the refrigerant system
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - STANDARD PROCEDURE -
REFRIGERANT SYSTEM RECOVERY).
2. Disconnect and isolate the negative battery cable.
3. Disconnect the A/C discharge line and the A/C liq-
uidlinefromtheA/Ccondenser(Referto24-
HEATING & AIR CONDITIONING/PLUMBING/
LINE-A/C DISCHARGE - REMOVAL) and (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING/
LINE-A/C LIQUID - REMOVAL).
4. Disconnect the wire harness connector (8) from the
A/C condenser cooling fan motor (7).

EMISSIONS CONTROL
DESCRIPTION
STATE DISPLAY TEST MODE
The switch inputs to the Powertrain Control Module (PCM) have two recognized states; HIGH and LOW. For this
reason, the PCM cannot recognize the difference between a selected switchposition versus an open circuit, a short
circuit, or a defective switch. If the State Display screen shows the changefromHIGHtoLOWorLOWtoHIGH,
assume the entire switch circuit to the PCM functions properly. Connect the DRB scan tool to the data link con-
nector and access the state display screen. Then access either State Display Inputs and Outputs or State Display
Sensors.
CIRCUIT ACTUATION TEST MODE
The Circuit Actuation Test Mode checks for proper operation of output circuits or devices the Powertrain Control
Module (PCM) may not internally recognize. The PCM attempts to activate these outputs and allow an observer to
verify proper operation. Most of the tests provide an audible or visual indication of device operation (click of relay
contacts, fuel spray, etc.). Except for intermittent conditions, if a device functions properly during testing, assume the
device, its associated wiring, and driver circuit work correctly. Connect the DRB scan tool to the data link connector
and access the Actuators screen.
DIAGNOSTIC TROUBLE CODES
A Diagnostic Trouble Code (DTC) indicates the PCM has recognized an abnormal condition in the system.
Remember that DTC’s are the results of a system or circuit failure, but do not directly identify the failed
component or components.
BULB CHECK
Each time the ignition key is turned to the ON position, the malfunction indicator (check engine) lamp on the instru-
ment panel should illuminate for approximately 2 seconds then go out. Thisis done for a bulb check.
OBTAINING DTC’S USING DRB SCAN TOOL
1. Obtain the applicable Powertrain Diagnostic Manual.
2. Obtain the DRB Scan Tool.
3. Connect the DRB Scan Tool to the data link (diagnostic) connector. This connector is located in the passenger
compartment at the lower edge of instrument panel, and near the steering column.
4. Turn the ignition switch on and access the “Read Fault” screen.
5. Record all the DTC’s and “freeze frame” information shown on the DRB scantool.
6. To erase DTC’s, use the “Erase Trouble Code” data screen on the DRB scan tool.Do not erase any DTC’s
until problems have been investigated and repairs have been performed.
TA S K M A N A G E R
The PCM is responsible for efficiently coordinating the operation of all the emissions-related components. The PCM
is also responsible for determining if the diagnostic systems are operating properly. The software designed to carry
out these responsibilities is called the ’Task Manager’.
MONITORED SYSTEMS
There are new electronic circuit monitors that check fuel, emission, engine and ignition performance. These moni-
tors use information from various sensor circuits to indicate the overalloperation of the fuel, engine, ignition and
emission systems and thus the emissions performance of the vehicle.
The fuel, engine, ignition and emission systems monitors do not indicate aspecific component problem. They do
indicate that there is an implied problem within one of the systems and thata specific problem must be diagnosed.
If any of these monitors detect a problem affecting vehicle emissions, theMalfunction Indicator Lamp (MIL) will be
illuminated. These monitors generate Diagnostic Trouble Codes that can be displayed with the MIL or a scan tool.

The following is a list of the system monitors:
Misfire Monitor
Fuel System Monitor
Oxygen Sensor Monitor
Oxygen Sensor Heater Monitor
Catalyst Monitor
Leak Detection Pump Monitor (if equipped)
All these system monitors require two consecutive trips with the malfunction present to set a fault.
Refer to the appropriate Powertrain Diagnostics Procedures manual for diagnostic procedures.
The following is an operation and description of each system monitor:
OXYGEN SENSOR (O2S) MONITOR
Effective control of exhaust emissions is achieved by an oxygen feedback system. The most important element of
the feedback system is the O2S. The O2S is located in the exhaust path. Once it reaches operating temperature
300° to 350°C (572° to 662°F), the sensor generates a voltage that is inversely proportional to the amount of oxy-
gen in the exhaust. The information obtained by the sensor is used to calculate the fuel injector pulse width. This
maintains a 14.7 to 1 Air Fuel (A/F) ratio. At this mixture ratio, the catalyst works best to remove hydrocarbons (HC),
carbon monoxide (CO) and nitrogen oxide (NOx) from the exhaust.
The O2S is also the main sensing element for the Catalyst and Fuel Monitors.
The O2S can fail in any or all of the following manners:
slow response rate
reduced output voltage
dynamic shift
shortedoropencircuits
Response rate is the time required for the sensor to switch from lean to richonce it is exposed to a richer than
optimum A/F mixture or vice versa. As the sensor starts malfunctioning, itcould take longer to detect the changes
in the oxygen content of the exhaust gas.
The output voltage of the O2S ranges from 0 to 1 volt. A good sensor can easilygenerate any output voltage in this
range as it is exposed to different concentrations of oxygen. To detect a shift in the A/F mixture (lean or rich), the
output voltage has to change beyond a threshold value. A malfunctioning sensor could have difficulty changing
beyond the threshold value.
OXYGEN SENSOR HEATER MONITOR
If there is an oxygen sensor (O2S) shorted to voltage DTC, as well as a O2S heater DTC, the O2S fault MUST be
repaired first. Before checking the O2S fault, verify that the heater circuit is operating correctly.
Effective control of exhaust emissions is achieved by an oxygen feedback system. The most important element of
the feedback system is the O2S. The O2S is located in the exhaust path. Once it reaches operating temperature
300°C to 350°C (572°F to 662°F), the sensor generates a voltage that is inversely proportional to the amount of
oxygen in the exhaust. The information obtained by the sensor is used to calculate the fuel injector pulse width. This
maintains a 14.7 to 1 Air Fuel (A/F) ratio. At this mixture ratio, the catalyst works best to remove hydrocarbons (HC),
carbon monoxide (CO) and nitrogen oxide (NOx) from the exhaust.
The voltage readings taken from the O2S sensor are very temperature sensitive. The readings are not accurate
below 572°F (300°C). Heating of the O2S sensor is done to allow the engine controllertoshifttoclosedloopcontrol
as soon as possible. The heating element used to heat the O2S sensor must be testedtoensurethatitisheating
the sensor properly.
The O2S sensor circuit is monitored for a drop in voltage. The sensor outputis used to test the heater by isolating
the effect of the heater element on the O2S sensor output voltage from the other effects.
LEAK DETECTION PUMP MONITOR (IF EQUIPPED)
The leak detection assembly incorporates two primary functions: it must detect a leak in the evaporative system and
seal the evaporative system so the leak detection test can be run.

The primary components within the assembly are: A three port solenoid thatactivates both of the functions listed
above; a pump which contains a switch, two check valves and a spring/diaphragm, a canister vent valve (CVV) seal
which contains a spring loaded vent seal valve.
Immediately after a cold start, between predetermined temperature thresholds limits, the three port solenoid is briefly
energized. This initializes the pump by drawing air into the pump cavity and also closes the vent seal. During non
test conditions the vent seal is held open by the pump diaphragm assembly which pushes it open at the full travel
position. The vent seal will remain closed while the pump is cycling due to the reed switch triggering of the three
port solenoid that prevents the diaphragm assembly from reaching full travel. After the brief initialization period, the
solenoid is de-energized allowing atmospheric pressure to enter the pumpcavity, thus permitting the spring to drive
the diaphragm which forces air out of the pump cavity and into the vent system. When the solenoid is energized
and de energized, the cycle is repeated creating flow in typical diaphragmpump fashion. The pump is controlled in
2 modes:
Pump Mode: The pump is cycled at a fixed rate to achieve a rapid pressure build in order to shorten the overall test
length.
Test Mode: The solenoid is energized with a fixed duration pulse. Subsequent fixed pulses occur when the dia-
phragm reaches the Switch closure point.
The spring in the pump is set so that the system will achieve an equalized pressure of about 7.5” H20. The cycle
rate of pump strokes is quite rapid as the system begins to pump up to this pressure. As the pressure increases, the
cycle rate starts to drop off. If there is no leak in the system, the pump would eventually stop pumping at the equal-
ized pressure. If there is a leak, it will continue to pump at a rate representative of the flow characteristic of the size
of the leak. From this information we can determine if the leak is larger than the required detection limit (currently
set at .040” orifice by CARB). If a leak is revealed during the leak test portion of the test, the test is terminated at
the end of the test mode and no further system checks will be performed.
After passing the leak detection phase of the test, system pressure is maintained by turning on the LDP’s solenoid
until the purge system is activated. Purge activation in effect creates a leak. The cycle rate is again interrogated and
when it increases due to the flow through the purge system, the leak check portion of the diagnostic is complete.
The canister vent valve will unseal the system after completion of the testsequence as the pump diaphragm assem-
bly moves to the full travel position.
Evaporative system functionality will be verified by using the stricter evap purge flow monitor. At an appropriate
warm idle the LDP will be energized to seal the canister vent. The purge flowwill be clocked up from some small
value in an attempt to see a shift in the02 control system. If fuel vapor, indicated by a shift in the 02 control, is
present the test is passed. If not, it is assumed that the purge system is notfunctioning in some respect. The LDP
is again turned off and the test is ended.
MISFIRE MONITOR
Excessive engine misfire results in increased catalyst temperature and causes an increase in HC emissions. Severe
misfires could cause catalyst damage. To prevent catalytic convertor damage, the PCM monitors engine misfire.
The Powertrain Control Module (PCM) monitors for misfire during most engine operating conditions (positive torque)
by looking at changes in the crankshaft speed. If a misfire occurs the speedof the crankshaft will vary more than
normal.
FUEL SYSTEM MONITOR
To comply with clean air regulations, vehicles are equipped with catalytic converters. These converters reduce the
emission of hydrocarbons, oxides of nitrogen and carbon monoxide. The catalyst works best when the Air Fuel (A/F)
ratio is at or near the optimum of 14.7 to 1.
The PCM is programmed to maintain the optimum air/fuel ratio of 14.7 to 1. This is done by making short term
corrections in the fuel injector pulse width based on the O2S sensor output. The programmed memory acts as a self
calibration tool that the engine controller uses to compensate for variations in engine specifications, sensor toler-
ances and engine fatigue over the life span of the engine. By monitoring theactual fuel-air ratio with the O2S sen-
sor (short term) and multiplying that with the program long-term (adaptive) memory and comparing that to the limit,
it can be determined whether it will pass an emissions test. If a malfunction occurs such that the PCM cannot main-
tain the optimum A/F ratio, then the MIL will be illuminated.

TA S K M A N A G E R
The Task Manager determines which tests happen when and which functions occur when. Many of the diagnostic
steps required by OBD II must be performed under specific operating conditions. The Task Manager software orga-
nizes and prioritizes the diagnostic procedures. The job of the Task Manager is to determine if conditions are appro-
priate for tests to be run, monitor theparameters for a trip for each test, and record the results of the test. Following
are the responsibilities of the Task Manager software:
Test Sequence
MIL Illumination
Diagnostic Trouble Codes (DTCs)
Trip Indicator
Freeze Frame Data Storage
Similar Conditions Window
Te s t S e q u e n c e
In many instances, emissions systems must fail diagnostic tests more thanonce before the PCM illuminates the
MIL. These tests are know as ’two trip monitors.’ Other tests that turn the MIL lamp on after a single failure are
known as ’one trip monitors.’ A trip is defined as ’start the vehicle and operate it to meet the criteria necessary to
run the given monitor.’
Many of the diagnostic tests must be performed under certain operating conditions. However, there are times when
tests cannot be run because another test is in progress (conflict), another test has failed (pending) or the Task
Manager has set a fault that may cause a failure of the test (suspend).
Pending
Under some situations the Task Manager will not run a monitor if the MIL is illuminated and a fault is stored
from another monitor. In these situations, the Task Manager postpones monitorspendingresolution of the
original fault. The Task Manager does not run the test until the problem is remedied.
For example, when the MIL is illuminated for an Oxygen Sensor fault, the Task Manager does not run the
Catalyst Monitor until the Oxygen Sensor fault is remedied. Since the Catalyst Monitor is based on signals
from the Oxygen Sensor, running the test would produce inaccurate results.
Conflict
There are situations when the Task Manager does not run a test if another monitor is in progress. In these
situations, the effects of another monitor running could result in an erroneous failure. If thisconflictis present,
themonitorisnotrununtiltheconflicting condition passes. Most likelythe monitor will run later after the con-
flicting monitor has passed.
For example, if the Fuel System Monitor is in progress, the Task Manager does not run the EGR Monitor.
Since both tests monitor changes in air/fuel ratio and adaptive fuel compensation, the monitors will conflict with
each other.
Suspend
Occasionally the Task Manager may not allow a two trip fault to mature. The Task Manager willsuspendthe
maturing of a fault if a condition exists that may induce an erroneous failure. This prevents illuminating the MIL
for the wrong fault and allows more precis diagnosis.
For example, if the PCM is storing a one trip fault for the Oxygen Sensor and the EGR monitor, the Task
Manager may still run the EGR Monitor but will suspend the results until theOxygen Sensor Monitor either
passes or fails. At that point the Task Manager can determine if the EGR system is actually failing or if an
Oxygen Sensor is failing.
MIL Illumination
The PCM Task Manager carries out the illumination of the MIL. The Task Manager triggers MIL illumination upon
test failure, depending on monitor failure criteria.
The Task Manager Screen shows both a Requested MIL state and an Actual MIL state. When the MIL is illuminated
upon completion of a test for a third trip, the Requested MIL state changes to OFF. However, the MIL remains
illuminated until the next key cycle. (On some vehicles, the MIL will actually turn OFF during the third key cycle)
During the key cycle for the third good trip, the Requested MIL state is OFF,while the Actual MIL state is ON. After
the next key cycle, the MIL is not illuminated and both MIL states read OFF.