engine DODGE RAM SRT-10 2006 Service Repair Manual

3.FUEL CONTROL ACTUATOR
Check for a mechanically stuck Fuel Control Actuator (FCA). Using the scantool, actuate the fuel control actuator.
NOTE: The fuel control actuator will only click when cycled off..
Do you hear a click from the actuator when you cycle the actuator off with thescan tool?
Ye s>>
Go To 4
No>>
Replace the fuel Injector pump.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
4.FUEL PRESSURE SENSOR
Using the scan tool, monitor the fuel pressure reading from the fuel rail pressure sensor at idle and at 2000 RPM
Is the fuel rail pressure reading higher at 2000 RPM than at idle?
Ye s>>
Go To 5
No>>
Replace the fuel pressure sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
5.HIGH FUEL PRESSURE
Using the scan tool compare the fuel rail pressure set point with the actualfuel rail pressure.
Is the actual fuel rail pressure higher than the fuel rail pressure set point?
Ye s>>
Go To 6
No>>
Go To 9
6.CASCADE OVERFLOW VALVE
Perform the no trouble code test*fuel pump return flow test. (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)
Did the fuel injection pump pass the test?
Ye s>>
Go To 7
No>>
Replace the Fuel pump.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
7.CHECK VALVE DAMAGED OR BLOCKED
Check the fuel drain line check valve in the rear of the cylinder head for signs of damage, blockage, or debris.
Is the check valve damaged or blocked?
Ye s>>
Repair the cause of the damaged or blocked check valve or replace the valve.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
No>>
Go To 8

8.FUEL RETURN LINE OBSTRUCTION, DAMAGED OR DEBRIS
Check the fuel return lines for signs of obstruction, damage, or debris.
Are the fuel drain lines damaged or blocked?
Ye s>>
Repair cause of high fuel drain line restriction.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
No>>
Go To 9
9.LIFT PUMP FLOW
Perform the no trouble code*LIFT PUMP FLOW TEST. (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)
Did the Lift pump pass the test?
Ye s>>
Go To 10
No>>
Replace the Lift Pump.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
10.PRESSURE LIMITING VALVE
Perform the no trouble code test*PRESSURE LIMITING VALVE ON THE FUEL RAIL FOR INTERNAL LEAKS.
Did the pressure limiting valve pass the test procedure?
Ye s>>
Go To 11
No>>
Replace the Pressure Limiting Valve.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
11 .LEAKING FUEL INJECTORS OR HIGH PRESSURE CONNECTORS
Perform the no trouble test*INJECTOR RETURN FLOW TEST. (Refer to 9 - ENGINE - DIAGNOSIS AND TEST-
ING)
Are any Injectors leaking or high pressure connectors leaking?
Ye s>>
Replace or repair the leaking fuel injectors or high pressure connectors.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
No>>
Go To 12
12.HIGH PRESSURE FUEL PUMP
Perform the no trouble code test*HIGH PRESSURE FUEL PUMP PERFORMANCE TEST. (Refer to 9 - ENGINE
- DIAGNOSIS AND TESTING)
Did the fuel pump pass the high pressure fuel pump performance test?
Ye s>>
Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure). (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING)
No>>
Replace the High pressure fuel pump.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)

When Monitored:
While the engine is running.
Set Condition:
Water in fuel light was on for a calibrated amount of time.
Possible Causes
OTHER DTC’S PRESENT
WATER IN FUEL
Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING)
Diagnostic Test
1.OTHER DTC’S PRESENT
With the scan tool, read DTCs.
Is P2269 displayed?
Ye s>>
Repair P2269 DTC first.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
No>>
Drain water in fuel.

When Monitored:
At key on.
Set Condition:
The fuel pressure sensor reading at key on does not match the expected fuel pressure reading at key on.
Possible Causes
OTHER DTC’S PRESENT
FUEL RAIL PRESSURE SENSOR
FUEL SYSTEM TAMPERING
INTERMITTENT CONDITION
Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING)
Diagnostic Test
1.OTHER DTC’S PRESENT
With the scan tool, read DTCs.
Are any DTC’s present?
Ye s>>
Repair other DTC’s first.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
No>>
Go To 2
2.FUEL PRESSURE READING
Using the scan tool, monitor the actual fuel pressure reading while the keyis on and engine is not running.
Is the actual fuel pressure reading greater than 870 psi?
Ye s>>
Go To 3
No>>
Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure). (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING)
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
3.FUEL RAIL PRESSURE SENSOR
Visually inspect the fuel system components for signs of tampering, pay particular attention to the fuel pressure
sensor on the fuel rail and the fuel pressure sensor wiring harness.
Were any signs of tampering discovered?
No>>
Replace the Fuel rail pressure sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
Ye s>>
Restore Fuel system to original condition.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)

When Monitored:
With the ignition on and battery voltage greater than 10.4 volts.
Set Condition:
The circuit voltage to the ECM falls below a calibrated threshold for a certain period of time.
Possible Causes
OTHER DTC’S
FUEL PRESSURE SENSOR
(F855) 5-VOLT SUPPLY CIRCUIT SHORTED TO (F855) RETURN CIRCUIT
(K181) SIGNAL CIRCUIT SHORTED TO (F855) RETURN CIRCUIT
(K181) SIGNAL CIRCUIT OPEN
(F855) 5-VOLT SUPPLY CIRCUIT OPEN
(K181) SIGNAL CIRCUIT SHORTED TO GROUND
(F855) 5-VOLT SUPPLY CIRCUIT SHORTED TO GROUND
ECM
INTERMITTENT CONDITION
Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING)
Diagnostic Test
1.OTHER DTC’S
Ignition on, engine not running.
With the scan tool, read DTCs.
Do you have multiple DTC’s?
Ye s>>
Repair other DTC’s first.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
No>>
Go To 2
2.(F855) 5-VOLT SUPPLY AND (K915) RETURN CIRCUIT
Turn the ignition off.
Disconnect the Fuel Pressure sensor harness connector.
NOTE: Check connectors - Clean/repair as necessary.
Ignition on, engine not running.
Measure the voltage between the (F855) 5-volt supply and (K915)
return circuits of the Fuel pressure sensor harness connector.
Is the voltage between 4.5 and 5.5 volts?
Ye s>>
Go To 3
No>>
Go To 4

3.FUEL PRESSURE SENSOR
Reconnect the disconnected Fuel Pressure Sensor harness connector.
While monitoring scan tool, disconnect the Fuel Pressure sensor harness connector.
Does the DTC P0193 set?
Ye s>>
Replace the Fuel Pressure Sensor.
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.(F855) 5-VOLT SUPPLY CIRCUIT SHORTED TO (K915) RETURN CIRCUIT
Turn the ignition off.
Disconnect the ECM harness connectors.
Disconnect the Fuel Pressure sensor harness connector.
Check connectors - Clean/repair as necessary.
Measure the resistance between the (F855) 5-volt supply circuit and
(K915) return circuit in the sensor harness connector.
Is the resistance greater than 100 K Ohms?
Ye s>>
Go To 5
No>>
Repair the shorted circuits.
Perform POWERTRAIN VERIFICATION TEST VER - 1
(DIESEL). (Refer to 8 - ELECTRICAL/ELECTRONIC CON-
TROL MODULES/ENGINE CONTROL MODULE - DIAG-
NOSIS AND TESTING)
5.(K181) SIGNAL CIRCUIT SHORTED TO (K915) RETURN CIRCUIT
Measure the resistance between the (K181) signal circuit and (K915)
return circuit in the sensor connector.
Is the resistance greater than 100 K Ohms?
Ye s>>
Go To 6
No>>
Repair the shorted circuits.
Perform POWERTRAIN VERIFICATION TEST VER - 1
(DIESEL). (Refer to 8 - ELECTRICAL/ELECTRONIC CON-
TROL MODULES/ENGINE CONTROL MODULE - DIAG-
NOSIS AND TESTING)

6.(K181) SIGNAL CIRCUIT OPEN
Measure the resistance between the signal (K181) circuit in the sensor
harness connector with the (K181) signal circuit in the ECM harness
connector.
Is the resistance less than 10 Ohms?
Ye s>>
Go To 7
No>>
Repair the open (K181) signal circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 1
(DIESEL). (Refer to 8 - ELECTRICAL/ELECTRONIC CON-
TROL MODULES/ENGINE CONTROL MODULE - DIAG-
NOSIS AND TESTING)
7.(F855) 5-VOLT SUPPLY CIRCUIT OPEN
Measure the resistance between the supply (F855) circuit in the sensor
harness connector with the (F855) 5-volt supply circuit in the ECM har-
ness connector.
Is the resistance less than 10 Ohms?
Ye s>>
Go To 8
No>>
Repair the open (F855) 5-volt supply circuit.
Perform POWERTRAIN VERIFICATION TEST VER - 1
(DIESEL). (Refer to 8 - ELECTRICAL/ELECTRONIC CON-
TROL MODULES/ENGINE CONTROL MODULE - DIAG-
NOSIS AND TESTING)

8.(K181) SIGNAL CIRCUIT SHORTED TO GROUND
Measure the resistance between the (K181) signal circuit in the sensor
harness connector and battery negative.
Is the resistance greater than 100 K Ohms?
Ye s>>
Go To 9
No>>
Repair (K181) signal circuit shorted to ground.
Perform POWERTRAIN VERIFICATION TEST VER - 1
(DIESEL). (Refer to 8 - ELECTRICAL/ELECTRONIC CON-
TROL MODULES/ENGINE CONTROL MODULE - DIAG-
NOSIS AND TESTING)
9.(F855) 5-VOLT SUPPLY CIRCUIT SHORTED TO GROUND
Measure the resistance between the (F855) 5-volt supply circuit in the
sensor harness connector and battery negative.
Is the resistance greater than 100 K Ohms?
Ye s>>
Go To 10
No>>
Repair (F855) 5-volt Supply circuit shorted to ground.
Perform POWERTRAIN VERIFICATION TEST VER - 1
(DIESEL). (Refer to 8 - ELECTRICAL/ELECTRONIC CON-
TROL MODULES/ENGINE CONTROL MODULE - DIAG-
NOSIS AND TESTING)
10.ECM
Reconnect the disconnected Fuel pressure sensor harness connector and ECM harness connectors.
While monitoring scan tool, disconnect the Fuel Pressure sensor connector.
Does the DTC P0193 set?
Ye s>>
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)
No>>
Replace the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)

When Monitored:
With the ignition on and battery voltage greater than 10.4 volts.
Set Condition:
The circuit voltage to the ECM is above a calibrated threshold for a certainperiod of time.
Possible Causes
OTHER DTC’S
FUEL PRESSURE SENSOR
(K181) SIGNAL CIRCUIT SHORTED TO VOLTAGE
(F855) 5-VOLT SUPPLY CIRCUIT SHORTED TO VOLTAGE
(K181) SIGNAL CIRCUIT SHORTED TO (F855) 5-VOLT SUPPLY CIRCUIT
(K915) RETURN CIRCUIT OPEN
ECM
INTERMITTENT CONDITION
Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING)
Diagnostic Test
1.OTHER DTC’S
Ignition on, engine not running.
With the scan tool, read DTCs.
Do you have multiple DTC’s?
Ye s>>
Refer to multiple fault troubleshooting tree.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
No>>
Go To 2
2.(F855) 5-VOLT SUPPLY AND (K915) RETURN CIRCUIT
Turn the ignition off.
Disconnect the Fuel Pressure sensor harness connector.
NOTE: Check connectors - Clean/repair as necessary.
Ignition on, engine not running.
Measure the voltage between the (F855) 5-volt supply and (K915)
return circuits of the Fuel pressure sensor harness connector.
Is the voltage between 4.5 and 5.5 volts?
Ye s>>
Go To 3
No>>
Go To 4

3.FUEL PRESSURE SENSOR
While monitoring scan tool, connect a jumper wire between the (K181)
signal circuit and the (K915) return circuit of the Fuel Pressure sensor
connector.
Does the DTC P0192 set?
Ye s>>
Replace the Fuel Pressure Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 1
(DIESEL). (Refer to 8 - ELECTRICAL/ELECTRONIC CON-
TROL MODULES/ENGINE CONTROL MODULE - DIAG-
NOSIS AND TESTING)
No>>
Go To 4
4.(K181) SIGNAL CIRCUIT SHORTED TO VOLTAGE
Turn the ignition off.
Disconnect the Fuel Pressure sensor harness connector.
Disconnect the ECM harness connectors.
Check connectors - Clean/repair as necessary.
Turn the ignition on.
Measure the voltage between the (K181) signal circuit of the sensor
harness connector and battery negative.
Is the voltage less than 1 volt?
Ye s>>
Go To 5
No>>
Repair the (K181) signal circuit shorted to voltage.
Perform POWERTRAIN VERIFICATION TEST VER - 1
(DIESEL). (Refer to 8 - ELECTRICAL/ELECTRONIC CON-
TROL MODULES/ENGINE CONTROL MODULE - DIAG-
NOSIS AND TESTING)
5.(F855) 5-VOLT SUPPLY CIRCUIT SHORTED TO VOLTAGE
Measure the voltage between the (F855) 5-volt supply circuit of the sen-
sor harness connector and battery negative.
Is the voltage less than 1 volt?
Ye s>>
Go To 6
No>>
Repair the (F855) 5-volt supply circuit shorted to voltage.
Perform POWERTRAIN VERIFICATION TEST VER - 1
(DIESEL). (Refer to 8 - ELECTRICAL/ELECTRONIC CON-
TROL MODULES/ENGINE CONTROL MODULE - DIAG-
NOSIS AND TESTING)