fuel filter DODGE RAM SRT-10 2006 Service Service Manual

3. Place a shop towel around the fuel injectors to catch any fluid that may possibly be under pressure in the cyl-
inder head. Remove the fuel injectors (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR -
REMOVAL).
4. With all injectors removed, rotatethe crankshaft using the crankshaftbarring tool (PN 7471–B).
5. Identify the fluid in the cylinders (coolant, fuel, oil, etc.).
6. Be sure all fluid has been removed from the cylinders.
7. Repair engine or components as necessary to prevent this problem from occurring again.
8. Squirt a small amount of engine oil into the cylinders to lubricate the walls. This will prevent damage on restart.
9. Install fuel injectors (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR - INSTALLATION).
10. Drain engine oil. Remove and discard the oil filter (Refer to 9 - ENGINE/LUBRICATION/OIL FILTER -
REMOVAL).
11. Installthedrainplug.Tightentheplugto50Nꞏm(37ft.lbs.)torque.
12. Install a new oil filter (Refer to 9 - ENGINE/LUBRICATION/OIL FILTER - INSTALLATION).
13. Fill engine crankcase with the specified amount and grade of oil (Referto LUBRICATION & MAINTENANCE/
FLUID TYPES - SPECIFICATIONS).
14. Connect the negative cable(s) to the battery.
15. Start the engine and check for any leaks.
REMOVAL - ENGINE
1. Disconnect both battery negative cables.
2. Disconnect engine grid heater harness at grid
heater relays.
3. Disconnect electrical connections from rear of alter-
nator.
4. Recover A/C refrigerant. (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - STANDARD
PROCEDURE).
5. Raise vehicle on a hoist.
6. Drain engine coolant (Refer to 7 - COOLING -
STANDARD PROCEDURE).
7. Remove engine oil drain plug and drain engine oil.
8. Reinstall drain plug. Tighten to 50 Nꞏm (37 ft. lbs.)
torque.
9. Lower the vehicle.
10. Remove fan (3) and fan drive (2). Refer to (Refer
to 7 - COOLING/ENGINE/RADIATOR FAN -
REMOVAL).

47. Install the cooling fan (3) and fan drive (2). (Refer
to 7 - COOLING/ENGINE/RADIATOR FAN -
INSTALLATION).
48. Install the fan shroud mounting bracket (3) and
shroud. (Refer to 7 - COOLING/ENGINE/RADIA-
TOR FAN - INSTALLATION).
49. Install the windshield washer bottle.
50. Install the upper radiator hose and clamps.
51. Raise vehicle.
52. Change oil filter and install new engine oil.
53. Fill the cooling system with coolant. (Refer to 7 -
COOLING - STANDARD PROCEDURE).
54. Connect grid heater harness at grid heater relays.
55. Connect electrical connections to rear of alterna-
tor.
56. Start the engine and inspect for engine oil, cool-
ant, and fuel leaks.
SPECIFICATIONS
SPECIFICATIONS - 5.9L DIESEL
GENERAL DESCRIPTION

CYLINDER HEAD
DESCRIPTION
The cylinder head is constructed of cast iron and is a one piece cross flow design with four valves per cylinder. The
arrangement of two intake and two exhaust valves per cylinder allows for a centrally located injector. The cylinder
head also includes an integral intake manifold, an integral thermostat housing, and a longitudal fuel return rifle,
which exits at the rear of the head. The 24 valve design also includes integrally cast valve guides and hardened
intake and exhaust valve seat inserts.
REMOVAL
1. Disconnect battery negative cables.
2. Raise vehicle on hoist.
3. Drain engine coolant.
4. Disconnect exhaust pipe from turbocharger elbow.
5. Remove turbocharger drain tube bolts at turbocharger. Cap off ports to prevent dirt or foreign material from enter-
ing.
6. Lower vehicle.
7. Disconnect air inlet temperature/pressure sensor.
8. Remove air cleaner housing and snorkel from the vehicle. Cap off turbocharger air inlet to prevent intrusion of
dirt or foreign material.
9. Disconnect cab heater core supply and return hoses from the cylinder head and heater pipe.
10. Disconnect turbocharger oil supply line at the turbocharger end. Cap off open ports to prevent intrusion of dirt
or foreign material.
11. Remove exhaust manifold-to-cylinder head bolts, spacers, heat shield, retention straps, and cab heater plumb-
ing. Remove exhaust manifold and turbocharger from the vehicle as an assembly.
12. Remove cooling fan/drive/shroud assembly. (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - REMOVAL)
13. Remove accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
14. Remove cooling fan support from cylinder block.
15. Remove upper generator bolt, loosen lower generator bolt, and rotate generator away from cylinder head.
16. Disconnect radiator upper hose from the thermostat housing.
17. Disconnect the Intake Air Temperature/Manifold Air Pressure, and Coolant Temperature sensor connectors.
18. Remove the engine harness to cylinder head attaching bolts and P-clipsat front of head.
19. Remove the intake air grid heater wires from the grid heater.
20. Remove engine oil level indicator tube attaching bolt at fuel filter housing bracket and inlet air connection..
21. Remove the charge air cooler-to-air inlet housing pipe.
22. Remove the engine wire harness attaching bolt and wire harness push-infastener from air inlet housing.
23. Remove the air inlet housing and intake grid heater from the intake manifold cover.
24. Remove the two grid heater harness-to-cylinder head attaching bolts at front of cylinder head.
NOTE: Extreme care should be used to keep dirt/debris from entering the fuel lines. Plastic caps should be
used on the ends of the fuel lines.
25.Remove the high pressure pump to fuel rail fuel line as follows:
a. Loosen fuel line nuts at fuel pump and at fuel rail.
b. Use a back-up wrench on the fitting at the fuel pump to keep it from loosening.
26. Remove the fuel rail to cylinder head fuel lines as follows:
a. Loosen No. 6 high pressure fuel line shield and position out of way.
b. Loosen the fuel line nuts at the fuel rail and at the cylinder head. Use a back-up wrench on HPC nut.
c. Remove the fuel line bracket bolts at the intake manifold cover.

27. Remove the engine lift bracket from the rear of the cylinder head.
28. Remove the fuel rail as follows:
a. Remove fuel rail pressure sensor connector.
b. Remove banjo fitting at pressure limiting valve.
c. Remove fuel rail bolts and fuel rail.
29. Remove the low pressure lines as follows:
a. Remove the fuel drain banjo fitting on the front side of fuel filter housing.
b. Remove the fuel drain banjo fitting on rear side of fuel filter housing.
c. Remove the fuel drain line support bracket on rear side of filter housing.
d. Disconnect fuel drain hose.
e. Remove banjo fitting at bottom of fuel filter housing.
f. Disconnect fuel supply hose at fuel filter.
30. Disconnect fuel heater, and water in fuel sensor.
31. Remove the fuel filter assembly-to-cylinder head bolts and remove filter assembly from vehicle.
32. Remove wire harness P-clip from cylinder head (located behind filter housing).
NOTE: For early builds. Verify that the cylinder head cover ground spring is retained in the cylinder head
cover.
33. Remove the cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) -
REMOVAL).
34.For early builds.Disconnect rocker housing injector harness connectors.
35. Remove injector harness nuts from injectors.

4. Install push rods into their original locations.Ve r i f y
that they are seated in the tappets.
5. Inspect rocker housing gasket for cuts and proper installation into groove. Replace if damaged.
6. Install rocker housing and bolts. Tighten to 24 Nꞏm (18 lb. ft.).
7. Install fuel injector (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR - INSTALLATION).
8. Lubricate valve stem tips and install the cross-
heads in their original locations.
9. Lubricate the rocker arms (1) and pedestals (2)
and install them in their original locations. Install
the bolts and torque them to 36 Nꞏm (27 ft. lbs.).
10. Verify that the valve lash settings are maintained
(Refer to 9 - ENGINE/CYLINDER HEAD/INTAKE/
EXHAUST VALVES & SEATS - STANDARD
PROCEDURE).
11. Install cylinder head cover gasket onto rocker housing.
12. Install injector harness nuts. Tighten to 1.25 Nꞏm (11 in. lbs.).
13. Connect injector harness connectors at cylinder head cover gasket.
14. Install wire harness P-clip to cylinder head behind filter housing 24 Nꞏm (18 ft. lbs.).
15. Connect the IAT/MAP sensor connector.
16. Install the fuel filter housing assembly and hand tighten mounting bolts, Do not torque at this time.
17. Connect WIF sensor, and fuel heater.
CAUTION: Failure to follow procedure will result in fuel leaks and/or fuelsystem failure.
18.Install the fuel rail and high pressure fuel lines as follows:
a. Hand tighten fuel rail bolts.
b. Hand tighten fuel drain line to pressure limiting valve. Hand tighten banjo bolt at fuel filter housing.
c. Hand tighten fuel rail-to-cylinder head high pressure fuel lines.

d. Install fuel line brace bolts-to-intake manifold finger tight for fuellines#2thru#5.
e. Install fuel line brace nut to rear lift bracket stud, finger tight, for fuel line #6.
f. Hand tighten fuel pump to fuel rail line.
g. Torque fuel line nuts at cylinder head to 30 Nꞏm ( 22 ft. lbs.).
h. Torque fuel line nuts at fuel rail to 30 Nꞏm (22 ft. lbs.)
i. Usingabackupwrench,torquefuelpumptofuelraillineto37Nꞏm(27ft.lbs.). At injection pump.
j. Torque fuel pump to fuel rail line to 37 Nꞏm (27 ft. lbs.) at fuel rail.
k. Torque fuel drain banjo bolt at pressure limiting valve and front of fuelfilter housing to 24 Nꞏm (18 ft. lbs.).
l. Torque fuel line brace bolts to 24 Nꞏm (18 ft. lbs.).
m. Torque fuel line brace nut to 24 Nꞏm (18 ft. lbs.).
n. Torque rail bolts to 24 Nꞏm (18 ft. lbs.).
o. Connect fuel pressure sensor.
p. Torque fuel filter mounting bolts to 24 Nꞏm (18 ft. lbs.).
19. Reposition number 6 fuel line shield and torque to 43 Nꞏm (32 ft. lbs.).
20. Install the fuel filter to injection pump low pressure line. Inspect and replace sealing washers if necessary.
Torque banjo bolts to 24 Nꞏm (18 ft. lbs.).
21. Connect fuel return line at back of cylinder head hand tight.
22. Connect fuel return line at filter housing hand tight.
23. Torque banjo connections at cylinder head and fuel filter housing to 24Nꞏm (18 ft. lbs.)
24. Install bracket to rear of filter housing. Torque to 24 Nꞏm (18 ft. lbs.).
25. Using new gaskets, install the intake grid heater and air inlet housing. Torque bolts to 24 Nꞏm (18 ft. lbs.).
26. Install wire harness P-clip and push on clip to air inlet housing.
27. Connect engine oil level indicator tube at fuel filter housing and at air inlet housing.
28. Install the charge air cooler-to-air inlet housing duct assembly. Torque all clamps to 11 Nꞏm (100 in. lbs.).
29. Connect intake grid heater wires.
30. Secure engine harness to front of cylinder head with bolt at four locations.
31. Connect engine coolant temperature sensor connector.
32. Connect radiator upper hose to thermostat housing.
33. Rotate generator into position. Install upper bolt and torque upper and lower bolts.
34. Install wire harness push-on clip below bracket.
35. Install wire harness P-clip to top of bracket.
36. Install fan support and torque to 32 Nꞏm (24 ft. lbs.).
37. Install cooling fan/drive refer to (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - INSTALLATION).
38. Install accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
39. Install exhaust manifold/turbocharger assembly, using new gaskets.Start all bolts/spacers by hand. Starting
from the center bolts out, Torque bolts to 43 Nꞏm (32 ft. lbs.), then retorque from the center out again.
40. Install exhaust manifold heat shield to exhaust manifold studs. Install retaining nuts.Torque to 24 Nꞏm (18 ft.
lbs.).
41. Install exhaust bolt retention straps across cylinders 5 & 6.
42. Using a new gasket, connect the turbocharger oil drain tube. Torque to 24Nꞏm(18ft.lbs.).
43. Perform the turbocharger pre-lube procedure. (Refer to 11 - EXHAUST SYSTEM/TURBOCHARGER SYSTEM/
TURBOCHARGER - INSTALLATION)
44. Connect the turbocharger oil supply line. Torque to 24 Nꞏm (18 ft. lbs.).
45. Install air cleaner housing and duct.
46. Connect air inlet temperature/pressure sensor.
47. Raise vehicle on hoist.

OIL
STANDARD PROCEDURE
STANDARD PROCEDURE - ENGINE OIL LEVEL
CAUTION: Do not overfill crankcase with engine
oil, oil foaming and oil pressure loss can result.
To ensure proper lubrication of an engine, the engine
oil must be maintained at an acceptable level. The
acceptable oil level is in the SAFE RANGE (3) on the
engine oil dipstick.
1. Position vehicle on level surface.
2. With engine OFF, allow approximately 15 minutes
for oil to settle to bottom of crankcase, remove
engine oil dipstick.
3. Wipe dipstick clean.
4. Replace dipstick and verify it is seated in the tube.
5. Remove dipstick, with handle held above the tip, take oil level reading.
6. Add oil only if level is below the SAFE RANGE area on the dipstick.
7. Replace dipstick.
STANDARD PROCEDURE - ENGINE OIL SERVICE
WARNING: HOT OIL CAN CAUSE PERSONAL INJURY.
NOTE: Change engine oil and filter at intervals specified in the owner’s manual.
1. Operate the engine until the water temperature reaches 60°C (140°F). Shut the engine off.
2. Use a container that can hold at least 14 liters (15 quarts) to hold the used oil. Remove the oil drain plug and
drain the used engine oil into the container.
3. Always check the condition of the used oil. This can give you an indication of engine problems that might exist.
Thin, black oil indicates fuel dilution.
Milky discoloration indicates coolant dilution.
4. Clean the area around the oil filter head. Remove the filter (Refer to 9 - ENGINE/LUBRICATION/OIL FILTER -
REMOVAL).
5. Install new oil filter (Refer to 9 - ENGINE/LUBRICATION/OIL FILTER - INSTA L L AT I O N ) .
6. Clean the drain plug and the sealing surface of the pan. Check the condition of the threads and sealing surface
on the oil pan and drain plug.
7. Install the drain plug. Tighten the plug to 50 Nꞏm (37 ft. lbs.) torque.
8. Use only High-Quality Multi-Viscosity lubricating oil in the Cummins Turbo Diesel engine. Choose the correct oil
for the operating conditions (Refer to LUBRICATION & MAINTENANCE/FLUID TYPES - DESCRIPTION).
9. Fill the engine with the correct grade of new oil (Refer to LUBRICATION & MAINTENANCE/FLUID CAPACITIES
- SPECIFICATIONS).
10. Start the engine and operate it at idle for several minutes. Check for leaks at the filter and drain plug.
11. Stop engine. Wait 15 minutes to allow the oil to drain back to the pan and check the level again.
USED ENGINE OIL DISPOSAL
Care should be exercised when disposing of used engine oil after it has beendrained from a vehicle’s engine.

MANIFOLD - INTAKE
REMOVAL
1. Disconnect the battery negative cables.
2. Remove the charge air cooler outlet tube (6) from
the air inlet housing (8).
3. Remove the engine oil dipstick tube mounting bolt.
4. Remove dipstick support at fuel filter housing. Posi-
tion dipstick tube to the side.
5. Disconnect the air grid heater power cables at the
cable mounting studs.
6. Remove the engine wiring harness connections at
the air inlet housing elbow.
7. Remove the four (4) air inlet housing mounting
bolts and remove the housing from top of the
heater elements.
8. Remove the intake air grid heater (1)from the
manifold.
9. Remove the high pressure fuel lines and fuel rail (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL LINES
- REMOVAL).
10. Disconnect manifold air temperature/pressure sensor connector.
11. Remove the remaining intake manifold cover-to-cylinder head bolts.
12. Remove the intake manifold cover and gasket. Keep the gasket material and any other material out of the air
intake.
13. Clean the intake manifold cover and cylinder head sealing surface.

CLEANING
Clean manifold in solvent and blow dry with compressed air.
Clean cylinder block gasket surfaces using a suitable solvent.
The plenum pan rail must be clean and dry (free of all foreign material).
INSPECTION
Inspect manifold for cracks.
Inspect mating surfaces of manifold for flatness with a straightedge.
INSTALLATION
1. Using a new gasket, install the intake manifold cover.
2. Install the cover-to-cylinder head bolts that do not hold down the fuel rail.Tightentheboltsto24Nꞏm(18ft.lbs.)
torque.
3. Install the high pressure rail and fuel lines (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL LINES -
INSTALLATION).
4. Using two (2) new gaskets, install the intake air grid heater and air inlet housing.
5. Connect the manifold air temperature/pressure sensor connector.
6. Install and tighten the air intake heater power supply nut to 14 Nꞏm (120 in. lbs.) torque.
7. Install oil dipstick tube support at fuel filter housing.
8. Install the engine oil dipstick tube and mounting bolt.
9. Position the charge air cooler outlet tube onto the air inlet housing. Tightentheclampsto11Nꞏm(100in.lbs.)
torque.
10. Attach the engine wire harness to the air inlet housing.
11. Prime the fuel system. Refer to the fuel priming procedure in Group 14, Fuel System.
12. Connect the battery negative cables.

ENGINE DIAGNOSIS - PERFORMANCE
CONDITION POSSIBLE CAUSES CORRECTION
ENGINE WILL NOT
CRANK1. Weak or discharged battery. 1. Charge or replace battery as necessary.
(Refer to 8 - ELECTRICAL/BATTERY
SYSTEM - DIAGNOSIS AND TESTING).
Check charging system. Refer to the
appropriate Diagnostic Information for
charging system diagnosis.
2. Corroded or loose battery
connections.2. Clean/tighten battery/starter connections.
3. Faulty starter or related circuits. 3. Check starting system. (Refer to8-
ELECTRICAL/STARTING - DIAGNOSIS
AND TESTING).
4. Seized accessory drive
component.4. Remove accessory drive belt and
attempt to start engine. If engine cranks,
repair/replace seized component.
5. Engine internal mechanical failure
or hydrostatic lock.5. (Refer to 9 - ENGINE - STANDARD
PROCEDURE - HYDROSTATIC LOCKED
ENGINE).
ENGINE CRANKS BUT
WILL NOT START1. No spark. 1. Check for spark. Refer to the appropriate
Diagnostic Information for ignition system
diagnosis.
2. No fuel. 2. Perform fuel pressure test. Refer to the
appropriate Diagnostic Information for fuel
system diagnosis.
3. Low or no engine compression. 3. Perform cylinder compression test.
(Refer to 9 - ENGINE - DIAGNOSIS AND
TESTING - CYLINDER COMPRESSION
PRESSURE TEST).
ENGINE LOSS OF
POWER1. Worn or incorrect gapped spark
plugs.1. Replace spark plugs or set gap.
2. Dirt or water in fuel system. 2. Clean system and replace fuel filter.
3. Faulty fuel pump. 3. Replace fuel pump.
4. Incorrect valve timing. 4. Correct valve timing.
5. Blown cylinder head gasket(s). 5. Replace cylinder head gasket(s).
6. Low compression. 6. Test cylinder compression. (Refer to 9 -
ENGINE - DIAGNOSIS AND TESTING -
CYLINDER COMPRESSION PRESSURE
TEST)
7. Burned, warped, or pitted valves. 7. Install new or reface valves as
necessary.
8. Plugged or restricted exhaust. 8. Replace parts as necessary.
9. Faulty ignition cables. 9. Replace ignition cables as necessary.
10. Faulty coil(s). 10. Test and replace as necessary.