warning DODGE RAM SRT-10 2006 Service User Guide

NOTE: Fuel pressure specification is 407 KPa +/- 34 KPa (59 psi +/- 5 psi).
CAUTION: Stop All Actuations.
Is the fuel pressure within specification now?
Ye s>>
Repair/replace fuel supply line as necessary.
Perform the POWERTRAIN VERIFICATION TEST. (Refer to 9 - ENGINE - STANDARD PROCEDURE)
No>>
Go To 4
4.CHECKING FUEL 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. Failure to follow
these instructions can result in personal injury or death.
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>>
Replace the Fuel Pump Module.
Perform the POWERTRAIN VERIFICATION TEST. (Refer to 9 - ENGINE - STANDARD PROCEDURE)
5.(A109) FUEL PUMP RELAY OUTPUT CIRCUIT OPEN
Turn the ignition off.
Remove the Fuel Pump Relay from the IPM.
Disconnect the Fuel Pump Module harness connector.
Measure the resistance of the (A109) Fuel Pump Relay Output circuit
from the relay connector to the fuel pump module connector.
Is the resistance below 5.0 ohms?
Ye s>>
Replace the Fuel Pump Relay.
Perform the POWERTRAIN VERIFICATION TEST. (Refer to
9 - ENGINE - STANDARD PROCEDURE)
No>>
Repair the open in the (A109) Fuel Pump Relay Output cir-
cuit.
Perform the POWERTRAIN VERIFICATION TEST. (Refer to
9 - ENGINE - STANDARD PROCEDURE)

*HARD START FUEL SYSTEM
For a complete wiring diagramRefer to Section 8W.
Possible Causes
FUEL CONTAMINATION
RESTRICTED FUEL SUPPLY LINE
FUEL PUMP INLET STRAINER PLUGGED
FUEL PUMP MODULE
FUEL INJECTOR(S)
Diagnostic Test
1.CHECKING 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 a scan tool, actuate the ASD Fuel System 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 2
Within Specification
Go To 4
2.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. Failure to follow
these instructions can result in personal injury or death.
Raise vehicle on hoist, and disconnect the fuel supply line at the fuel pumpmodule.
Install special tool #6539 (5/16
) #6631(3/8) fuel line adapter and the fuel pressure gauge between the fuel supply
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.
NOTE: Fuel pressure specification is 407 KPa +/- 34 KPa (59 psi +/- 5 psi).
Is the fuel pressure within specification?
Ye s>>
Visually and physically inspect the fuel supply lines between the fuel tank and the fuel rail. Repair/re-
place as necessary.
Perform the POWERTRAIN VERIFICATION TEST. (Refer to 9 - ENGINE - STANDARD PROCEDURE)
No>>
Go To 3

3.CHECKING THE FUEL 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. Failure to follow
these instructions can result in personal injury or death.
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>>
Replace the Fuel Pump Module.
Perform the POWERTRAIN VERIFICATION TEST. (Refer to 9 - ENGINE - STANDARD PROCEDURE)
4.FUEL PUMP MODULE
NOTE: Before continuing visually and physically inspect the fuel delivery system for external leaks or dam-
age. Repair / replace as necessary.
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 special tool #6539 (5/16
) or #6631 (3/8) fuel line adapter.
Install the fuel pressure gauge.
Start the engine and allow the fuel system to reach maximum pressure.
Turn the ignition off.
NOTE: Fuel specification is 407 KPa +/- 34 KPa (59 psi +/- 5 psi).
Using special tool #C4390, Hose Clamp Pliers, pinch the rubber fuel line between the fuel pressure gauge and the
engine.
Monitor the fuel pressure gauge for a minimum of 5 minutes.
NOTE: The pressure should not fall below 241 KPa (35 psi)
Does the fuel pressure drop?
Ye s>>
Replace Fuel Pump Module.
Perform the POWERTRAIN VERIFICATION TEST. (Refer to 9 - ENGINE - STANDARD PROCEDURE)
No>>
Go To 5
5.FUEL INJECTOR(S)
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.
Remove special tool #C4390.
Start the engine and allow the fuel system to reach maximum pressure.
Turn the ignition off.
NOTE: Fuel specification is 407 KPa +/- 34 KPa (59 psi +/- 5 psi).
Move special tool #C4390, Hose Clamp Pliers, from between the fuel pressure gauge and the engine to between
the fuel pressure gauge and fuel pump module.
Monitor the fuel pressure gauge for a minimum of 5 minutes.

*FUEL PRESSURE LEAK DOWN
For a complete wiring diagramRefer to Section 8W.
Possible Causes
FUEL PUMP MODULE
FUEL INJECTOR(S)
Diagnostic Test
1.FUEL PUMP MODULE
NOTE: Before continuing visually and physically inspect the fuel delivery system for external leaks or dam-
age. Repair / replace as necessary.
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 special tool #6539 (5/16
) or #6631 (3/8) fuel line adapter.
Install the fuel pressure gauge.
Start the engine and allow the fuel system to reach maximum pressure.
Turn the ignition off.
NOTE: Fuel specification is 407 KPa +/- 34 KPa (59 psi +/- 5 psi).
Using special tool #C4390, Hose Clamp Pliers, pinch the rubber fuel line between the fuel pressure gauge and the
engine.
Monitor the fuel pressure gauge for a minimum of 5 minutes.
NOTE: The pressure should not fall below 241 KPa (35 psi)
Does the fuel pressure drop?
Ye s>>
Replace Fuel Pump Module.
Perform the POWERTRAIN VERIFICATION TEST. (Refer to 9 - ENGINE - STANDARD PROCEDURE)
No>>
Go To 2
2.FUEL INJECTOR(S)
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.
Remove special tool #C4390.
Start the engine and allow the fuel system to reach maximum pressure.
Turn the ignition off.
NOTE: NOTE: Fuel specification is 407 KPa +/- 34 KPa (59 psi +/- 5 psi).
Move special tool #C4390, Hose Clamp Pliers, from between the fuel pressure gauge and the engine to between
the fuel pressure gauge and fuel pump module.
Monitor the fuel pressure gauge for a minimum of 5 minutes.
NOTE: The pressure should not fall below 241 KPa (35 psi)
Does the fuel pressure drop?
Ye s>>
Replace the leaking fuel injectors.
Perform the POWERTRAIN VERIFICATION TEST. (Refer to 9 - ENGINE - STANDARD PROCEDURE)
No>>
Te s t C o m p l e t e .

Possible Causes
MECHANICAL CONDITION
BATTERY CIRCUIT RESISTANCE TOO HIGH
FUSED IGNITION SWITCH OUTPUT CIRCUITS
FUSED B+ CIRCUIT OPEN
(T752) STARTER RELAY CONTROL CIRCUIT OPEN
(T750) STARTER RELAY OUTPUT CIRCUIT OPEN
TRANSMISSION RANGE SENSOR
STARTER RELAY
STARTER
Diagnostic Test
1.MECHANICAL CONDITION
NOTE: Verify the battery is fully charged and capable of passing a load testbefore continuing.
WARNING: Make sure the battery is disconnected, then wait two minutes before proceeding. Failure to do
so may result in personal injury or possible death.
Turn the engine over by hand to make sure the engine is not seized.
Is the engine able to turn over?
Ye s>>
Go To 2
No>>
Repair the mechanical condition preventing the starter motor from cranking.
Perform the POWERTRAIN VERIFICATION TEST. (Refer to 9 - ENGINE - STANDARD PROCEDURE)
2.TRANSMISSION RANGE SENSOR
Turn the ignition off.
Disconnect the TRS harness connectors.
Move the Gear selector through all gear positions, from Park to 1st and
back.
While moving the gear selector through each gear, measure the resis-
tance between ground and the TRS (T41) Sense (P/N Position Switch
Sense) circuit at the TRS connector.
NOTE: The circuit is grounded in Park and Neutral and open in the
other positions.
Did the resistance change from above 100 kohms (open) to
below 10.0 ohms (grounded) ?
Ye s>>
Go To 3
No>>
Replace the Transmission Range Sensor.
Perform the POWERTRAIN VERIFICATION TEST. (Refer to
9 - ENGINE - STANDARD PROCEDURE)

3.EXCESSIVE RESISTANCE IN THE BATTERY CIRCUIT
Turn the ignition off.
Check the Battery Cables for excessive resistance using the service information procedure.
Did either Battery Cable have a voltage drop greater than 0.2 of a volt?
Ye s>>
Repair the excessive resistance in the Battery circuit.
Perform the POWERTRAIN VERIFICATION TEST. (Refer to 9 - ENGINE - STANDARD PROCEDURE)
No>>
Go To 4
4.STARTER RELAY
Turn ignition off.
Remove the Starter Relay from IPM.
CAUTION: The Parking Brake must be on and the Transmission must be in park for a vehicle equipped with
an automatic transmission.
WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands
near the pulleys, belts, or fan. Do notwear loose clothing. Failure to follow these instructions can result in
personal injury or death.
Briefly connect a jumper wire from the Internal Fused B+ circuit to the (T750) Starter Relay Output circuit.
Did the Starter Motor crank the engine?
Ye s>>
Go To 5
No>>
Go To 7
5.(T751) FUSED IGNITION SWITCH OUTPUT CIRCUIT
Ignition on, engine not running.
Using a 12-volt test light, probe the (T751) Fused Ignition Switch Output circuit in the Starter Relay connector.
While observing 12-volt test light, hold ignition key in the start position.
Does the test light illuminate brightly?
Ye s>>
Go To 6
No>>
Repair the excessive resistance in the(T751)FusedIgnitionSwitchOutput circuit. Inspect related fuses
and repair as necessary.
Perform the POWERTRAIN VERIFICATION TEST. (Refer to 9 - ENGINE - STANDARD PROCEDURE)

INTERMITTENT CONDITION
For a complete wiring diagramRefer to Section 8W.
POSSIBLE CAUSES
INTERMITTENT CONDITION
Diagnostic Test
1.INTERMITTENT CONDITION
NOTE: The conditions that set the DTC are not present at this time. The following list may help in identi-
fying the intermittent condition.
WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands
near the pulleys, belts, or fan. Do notwear loose clothing. Failure to follow these instructions can result in
personal injury or death.
Refer to any Technical Service Bulletins (TSBs) that may apply.
Review the scan tool Freeze Frame information. If possible, try to duplicate the conditions under which the DTC set.
With the engine running at normal operating temperature, monitor the scantool parameters relatedtotheDTCwhile
wiggling the wire harness. Look for parameter values to change and/or a DTCto set.
Turn the ignition off.
Visually inspect the related wire harness. Disconnect all the related harness connectors. Look for any chafed,
pierced, pinched, partially broken wires and broken, bent, pushed out, orcorroded terminals.
Perform a voltage drop test on the related circuits between the suspected faulty component and the ECM.
Inspect and clean all ECM, engine, and chassis grounds that are related to the most current DTC.
If numerous trouble codes were set, use a wire schematic and look for any common ground or supply circuits.
For any Relay DTCs, actuate the Relay with the scan tool and wiggle the related wire harness to try to interrupt the
actuation.
For intermittent Evaporative Emission trouble codes perform a visual andphysical inspection of the related parts
including hoses and the Fuel Filler cap.
For intermittent Misfire DTC’s check for restrictions in the Intake and Exhaust system, proper installation of Sensors,
vacuum leaks, and binding components that are run by the accessory drive belt.
Use the scan tool to perform a System Test if one applies to failing component.
A co-pilot, data recorder, and/or lab scope should be used to help diagnoseintermittent conditions.
Were any problems found during the above inspections?
Ye s>>
Perform the necessary repairs.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No>>
Te s t C o m p l e t e .

*INTAKE AIR SYSTEM PRESSURE TEST
Diagnostic Test
1.CHARGE AIR COOLER PRESSURE TEST
Loosen air inlet tube clamp at the turbocharger.
Remove the air filter housing and the inlet tube from the vehicle as an assembly.
Install the CAC Pressure Tester #9022 into the inner diameter of the turbocharger, securing it in place with the
supplied three-fingered band clamp, tighten tool clamp to 8n.m (72 in lbs).
NOTE: NEVER ATTEMPT TO START OR RUN THE VEHICLE AT ANY TIME DURING THIS TEST,ENGINE DAM-
AGE MAY OCCUR.
Fasten the safety chain around a solid surface behind the turbocharger. Warning: Never run CAC Pressure test
without the safety chain securely fastened.
Before attaching shop air to the pressure regulator verify that the regulator is at its lowest pressure setting (0 psi).
Attach an air supply to the regulator and slowly increase the pressure until the pressure gauge reads 20 psi.
WARNING: WARNING: Never apply more than 20 PSI.
Using a solution of soap and water spray the Turbocharger, Turbocharger wastegate, Charge Air Cooler Heat
Exchange and CAC Hoses while watching for leaks.
Before any attempt to repair the CAC system is made, its necessary to completely discharge the system. This can
be accomplished by turning the regulator knob counter-clockwise.
Allow for adequate time to pass before removing the CAC Pressure tester from the turbo charger inlet.
Position the Air Filter Housing over thethreemountingstudslocatedonthe inside front fender well and press down
firmly to lock housing into place.
Install Air Inlet Tube over the Turbocharger inlet and torque the band clampto35in.lbs.
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)

INTERMITTENT CONDITION
For a complete wiring diagramRefer to Section 8W.
POSSIBLE CAUSES
INTERMITTENT CONDITION
Diagnostic Test
1.INTERMITTENT CONDITION
NOTE: The conditions that set the DTC are not present at this time. The following list may help in identi-
fying the intermittent condition.
WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands
near the pulleys, belts, or fan. Do notwear loose clothing. Failure to follow these instructions can result in
personal injury or death.
Refer to any Technical Service Bulletins (TSBs) that may apply.
Review the scan tool Freeze Frame information. If possible, try to duplicate the conditions under which the DTC set.
With the engine running at normal operating temperature, monitor the scantool parameters relatedtotheDTCwhile
wiggling the wire harness. Look for parameter values to change and/or a DTCto set.
Turn the ignition off.
Visually inspect the related wire harness. Disconnect all the related harness connectors. Look for any chafed,
pierced, pinched, partially broken wires and broken, bent, pushed out, orcorroded terminals.
Perform a voltage drop test on the related circuits between the suspected faulty component and the PCM.
Inspect and clean all PCM, engine, and chassis grounds that are related to the most current DTC.
If numerous trouble codes were set, use a wire schematic and look for any common ground or supply circuits.
For any Relay DTCs, actuate the Relay with the scan tool and wiggle the related wire harness to try to interrupt the
actuation.
For intermittent Evaporative Emission trouble codes perform a visual andphysical inspection of the related parts
including hoses and the Fuel Filler cap.
For intermittent Misfire DTC’s check for restrictions in the Intake and Exhaust system, proper installation of Sensors,
vacuum leaks, and binding components that are run by the accessory drive belt.
Use the scan tool to perform a System Test if one applies to failing component.
A co-pilot, data recorder, and/or lab scope should be used to help diagnoseintermittent conditions.
Were any problems found during the above inspections?
Ye s>>
Perform the necessary repairs.
Perform POWERTRAIN VERIFICATION TEST VER - 1.
No>>
Te s t C o m p l e t e .

Theory of Operation
The engine coolant temperature sensor is a negative temperature coefficient thermistor-type sensor whose resis-
tance varies inversely with temperature. At cold temperatures the sensorresistance is high so the voltage is high.
As the coolant temperature increases the resistance decreases and the voltage becomes low. The INSUFFICIENT
COOLANT TEMP FOR CLOSED-LOOP FUEL CONTROL determines if the engine coolant temperature will reach
theclosedloopfuelingcontroltemperaturelimitinaregulatedtimeafterstart.
When Monitored:
With battery voltage greater than 10.4 volts and after engine is started.
Set Condition:
The engine temperature does not go above -10°C (15°F). Failure time depends on start-up coolant tempera-
ture and ambient temperature. (i.e. 2 minutes for a start temp of -10°C (15°F) or up to 10 minutes for a vehicle
with a start-up temp of -28°C (5°F). Two Trip Fault. Three good trips to turnoff the MIL.
Possible Causes
LOW COOLANT LEVEL
THERMOSTAT
ECT SENSOR
Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING).
Diagnostic Test
1.CHECKING COOLANT LEVEL AND CONDITION
Ignition on, engine not running.
With a scan tool, read DTCs.
NOTE: If an Engine Coolant Temperature (ECT) DTC is set along with this code, diagnose the ECT DTC first.
NOTE: Inspect the ECT terminals and related PCM terminals. Make sure the terminals are free from corro-
sion and damage.
NOTE: The best way to diagnose this DTC is to allow the vehicle to sit overnight outside in order to have
a totally cold soaked engine.
NOTE: Extremely cold outside ambient temperatures may have caused this DTCtoset.
WARNING: Never open the cooling system when the engine is hot. The system isunder pressure. Extreme
burns or scalding may result. Failure to follow these instructions can result in personal injury or death.
Allow the engine to cool before opening the cooling system.
Inspect the coolant system for proper level and condition.
Is the coolant level and condition OK?
Ye s>>
Go To 2
No>>
Inspect the vehicle for a coolant leak, make the appropriate repairs, and add the correct amount of
coolant.
Perform the POWERTRAIN VERIFICATION TEST. (Refer to 9 - ENGINE - STANDARD PROCEDURE)