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message off. If the problem persists, the message will appear the next time the vehicle is started. This might indicate a damaged cap. If the problem is detected twice in a row, turn on the Malfunction Indicator Light (MIL). Resolving the problem will turn the MIL light off.
the system will
EMISSIONS INSPECTION AND MAINTENANCE PROGRAMS In some localities, it may be a legal requirement to pass an inspection of your vehicle’s emissions control system. Failure to pass could prevent vehicle registration.
For states which have an I/M (Inspection and Maintenance) requirement, this check verifies the following: the MIL (Malfunction Indicator Lamp) is functioning and is not on when the engine is running, and that the OBD (On Board Diagnostic) system is ready for testing.
Normally, the OBD system will be ready. The OBD system may not be ready if your vehicle was recently serviced, if you recently had a dead battery, or a battery replacement. If the OBD system should be determined not ready for the I/M test, your vehicle may fail the test. Your vehicle has a simple ignition key actuated test which you can use prior to going to the test station. To check if your vehicle’s OBD system is ready, you must do the following: 1. Insert your ignition key into the ignition switch. 2. Turn the ignition to the ON position, but do not crank or start the engine. 3. If you crank or start the engine, you will have to start this test over. 4. As soon as you turn your key to the ON position, you will see your MIL symbol come on as part of a normal bulb check.
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Regardless of whether your vehicle’s OBD system is ready or not ready, if the MIL symbol is illuminated during normal vehicle operation, you should have your vehicle serviced before going to the I/M station. The I/M station can fail your vehicle because the MIL symbol is on with the engine running.
REPLACEMENT PARTS Use of genuine Mopart parts for normal/scheduled maintenance and repairs is highly recommended to in- sure the designed performance. Damage or failures caused by the use of non-Mopar parts for maintenance and repairs will not be covered by the manufacturer’s warranty.
5. Approximately 15 seconds later, one of two things will happen:
a. The MIL light will blink for approximately 5 sec- onds and then remain on until the first engine crank or the key is turned off. This means that your vehicle’s OBD system is not ready and you should not proceed to the I/M station. b. The MIL light will remain fully illuminated until the first engine crank or the key is turned off. This means that your vehicle’s OBD system is ready and you can proceed to the I/M station.
If your OBD system is not ready, you should see your dealer or repair facility. If your vehicle was recently serviced or had a battery failure or replacement, you may need to do nothing more than drive your vehicle as you normally would in order for your OBD system to update. A recheck with the above test routine may then indicate that the system is now ready.
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DEALER SERVICE Your dealer has the qualified service personnel, special tools and equipment to perform all service operations in an expert manner. Service manuals are available which include detailed service information for your vehicle. Refer to these manuals before attempting any procedure yourself. NOTE: systems can result against you.
Intentional tampering with emissions control in civil penalties being assessed
WARNING!
You can be badly injured working on or around a motor vehicle. Do only that service work for which you have the knowledge and the proper equipment. If you have any doubt about your ability to perform a service job, take your vehicle to a competent mechanic.
MAINTENANCE PROCEDURES The pages that follow contain the required maintenance services determined by the engineers who designed your vehicle. Besides the maintenance items for which there are fixed maintenance intervals, there are other items that should operate satisfactorily without periodic maintenance. However, if a malfunction of these items does occur, it
could adversely affect the engine or vehicle performance. These items should be inspected if a malfunction is observed or suspected. Engine Oil
Checking Oil Level To assure proper lubrication of your vehicle’s engine, the engine oil must be maintained at the correct level. The best time to check the engine oil level is about 5 minutes after a fully warmed up engine is shut off or before starting the engine after it has sat overnight. Checking the oil while the vehicle is on level ground will improve the accuracy of the oil level readings. Maintain the oil level between the ADD and SAFE markings on the dipstick. Adding one quart of oil when the reading is at the ADD mark will result in a SAFE reading on these engines.
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CAUTION!
Overfilling or underfilling the crankcase will cause oil aeration or loss of oil pressure. This could dam- age your engine.
390 MAINTAINING YOUR VEHICLE
Change Engine Oil Road conditions as well as your kind of driving affect the interval at which your oil should be changed. Check the following to determine if any apply to you: † Day or night temperatures are below 32°F (0°C). † Stop and go driving. † Extensive engine idling. † Driving in dusty conditions † Short trips of less than 10 miles (16.2 km) † More than 50% of your driving is at sustained high † Trailer towing † Heavy Loading † Taxi, Police or delivery service (commercial service)
speeds during hot weather, above 32°C (90°F)
† Off-road or desert operation † If equipped for and operating with E-85 (ethanol)
fuel.
If ANY of these apply to you then change your NOTE: engine oil every 3,000 miles (5 000 km) or 3 months, whichever comes first and follow schedule “B” of the 9Maintenance Schedules9 section of this manual. If none of these apply to you, then change your engine oil at every interval shown on schedule 9A9 of the 9Mainte- nance Schedules9 section of this manual. NOTE: Under no circumstances should oil change in- tervals exceed 6,000 miles (10 000 km) or 6 months whichever comes first. Dusty Conditions Driving through dust-laden air increases the problems of keeping abrasive materials out of the engine. Under these conditions, special attention should be given to the
engine air cleaner, the crankcase inlet air cleaner and the crankcase ventilation system. Make sure that these units are clean at all times. This will tend to reduce to a minimum the amount of abrasive material that may enter the engine. Engine Oil Selection For best performance and maximum protection under all types of operating conditions, the manufacture only recommends engine oils that are API certified and meet the requirements of DaimlerChrysler Material Standard MS-6395. Use Mopar or an equivalent oil meeting the specification MS-6395. American Petroleum Institute (API) Engine Oil Identification Symbol There is a symbol to aid you in selecting the proper engine oil.
MAINTAINING YOUR VEHICLE 391
This symbol means that the oil has been certified by the American Petroleum Institute (API). The manufacture only recommends API Certified engine oils.
Engine Oil Viscosity (SAE Grade) For trucks with a 5.7L engine operating under a gross combined weight rating of 14,000 lbs. or greater, SAE 5W-30 engine oil is recommended for all operating temperatures. For all other trucks with a 5.7L engine, operating under a gross weight rating less than 14,000
lbs. SAE 5W-20 engine oil is recommended for all operating temperatures. This engine oil improves low temperature starting and vehicle fuel economy. Your engine oil filler cap also shows the recommended engine oil viscosity for your vehicle392 MAINTAINING YOUR VEHICLE
For information on engine oil filler cap location, see the Engine Compartment illustration in this section. Lubricants which do not have both, the engine oil certi- fication mark and the correct SAE viscosity grade num- ber should not be used. Synthetic Engine Oils You may use synthetic engine oils provided the recom- mended oil quality requirements are met, and the recom- mended maintenance intervals for oil and filter changes are followed. Materials Added to Engine Oil The manufacture strongly recommends against the addi- tion of any additives (other than leak detection dyes) to the engine oil. Engine oil is an engineered product and it’s performance may be impaired by supplemental ad- ditives.
Disposing of Used Engine Oil And Oil Filters Care should be taken in disposing of used engine oil and oil filters from your vehicle. Used oil and oil filters, indiscriminately discarded, can present a problem to the environment. Contact your dealer, service station, or governmental agency for advice on how and where used oil and oil filters can be safely discarded in your area. Engine Oil Filter The engine oil filter should be replaced at every engine oil change. Engine Oil Filter Selection The manufacturer’s engines have a full-flow type oil filter. Use a filter of this type for replacement. The quality of replacement filters varies considerably. Only high quality filters should be used to assure most efficient service. Mopar Engine Oil Filters are a high quality oil filter and are recommended.
Drive Belts — Check Condition and Tension Belt tension is controlled by means of an automatic tensioner. No belt tension adjustments are required. However, belt and belt tensioner condition should be inspected at the specified intervals and replaced if re- quired. See your authorized dealer for service. At the mileage indicated in the maintenance schedule, all belts and tensioner should be checked for condition. Improper belt tension can cause belt slippage and failure. Belts should be inspected for evidence of cuts, cracks, glazing or frayed cords and replaced if there is indication of damage which could result in belt failure. Low gen- erator belt tension can cause battery failure. Also check belt routing to make sure there is no interfer- ence between the belts and other engine components.
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Spark Plugs Spark plugs must fire properly to assure engine perfor- mance and emission control. New plugs should be in- stalled at the specified mileage. The entire set should be replaced if there is any malfunction due to a faulty spark plug, malfunctioning spark plugs can damage the cata- lytic converter. For proper type of replacement spark plugs, refer to the “Vehicle Emission Control Informa- tion” label in the engine compartment. Spark Plug Wires — IF Equipped The spark plug wires should be kept clean and properly connected. Terminals should be fully seated. Cracked, damaged, or faulty wires should be replaced. Engine Air Cleaner Filter Under normal driving conditions, replace the air filter at the intervals shown on Schedule “A”. If, however, you
394 MAINTAINING YOUR VEHICLE
drive the vehicle frequently under dusty or severe con- ditions, the filter element should be inspected periodi- cally and replaced if necessary at the intervals shown on Schedule “B”.
WARNING!
The air induction system (air cleaner, hoses, etc) can provide a measure of protection in the case of engine backfire. Do not remove the air induction system (air cleaner, hoses, etc) unless such removal is necessary for repair or maintenance. Make sure that no one is near the engine compartment before starting the vehicle with the air induction system (air cleaner, hoses, etc) removed. Failure to do so can result in serious personal injury.
Engine Fuel Filter A plugged fuel filter can cause stalling, limit the speed at which a vehicle can be driven or cause hard starting. Should an excessive amount of dirt accumulate in the fuel tank, frequent filter replacement may be necessary. Catalytic Converter The catalytic converter requires the use of unleaded fuel only. Leaded gasoline will destroy the effectiveness of the catalyst as an emission control device. Under normal operating conditions, the catalytic con- verter will not require maintenance. However, it is im- portant to keep the engine properly tuned to assure proper catalyst operation and prevent possible catalyst damage.
CAUTION!
Damage to the catalytic converter can result if your vehicle is not kept in proper operating condition. In the event of engine malfunction, particularly involv- ing engine misfire or other apparent loss of perfor- mance, have your vehicle serviced promptly. Contin- ued operation of your vehicle with a severe malfunction could cause the converter to overheat, resulting in possible damage to the converter and the vehicle.
NOTE: systems can result against you.
Intentional tampering with emissions control in civil penalties being assessed
MAINTAINING YOUR VEHICLE 395
WARNING!
A hot exhaust system can start a fire if you park over materials that can burn. Such materials might be grass or leaves coming into contact with your ex- haust system. Do not park or operate your vehicle in areas where your exhaust system can contact any- thing that can burn.
In unusual situations involving grossly malfunctioning engine operation, a scorching odor may indicate severe and abnormal catalyst overheating. If this occurs, the vehicle should be stopped, the engine shut off and the vehicle allowed to cool. Thereafter, service, including a tune-up to manufacturer’s specifications, should be ob- tained immediately.
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To minimize the possibility of catalyst damage: † Do not shut off the engine or interrupt the ignition when the transmission is in gear and the vehicle is in motion. † Do not try to start engine by pushing or towing the † Do not idle the engine with any spark plug wires disconnected or removed, such as when diagnostic testing, or for prolonged periods during very rough idling or malfunctioning operating conditions.
vehicle.
Emission-Related Components
the intervals specified.
Positive Crankcase (PCV) Valve Proper operation of the crankcase ventilation system requires that the PCV valve be free of sticking or plug- ging from deposits. Deposits can accumulate in the PCV valve and passages with increasing mileage. Have the PCV valve, hoses, and passages checked for proper operation at the valve is plugged or sticking, replace with a new valve— do not attempt to clean the old PCV valve! Check the ventila- tion hoses for indications of damage, weepage or plug- ging with deposits. Replace if necessary. Maintenance Free Battery The top of the maintenance free battery is permanently sealed. You will never have to add water, nor is periodic maintenance required.
If
WARNING!
CAUTION!
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Battery fluid is a corrosive acid solution and can burn or even blind you. Don’t allow battery fluid to contact your eyes, skin or clothing. Don’t lean over a battery when attaching clamps. If acid splashes in eyes or on skin, flush the area immediately with large amounts of water. Battery gas is flammable and explosive. Keep flame or sparks away from the battery. Don’t use a booster battery or any other booster source with an output greater than 12 volts. Don’t allow cable clamps to touch each other. Battery posts, terminals and related accessories con- tain lead and lead compounds. Wash hands after handling.
It is essential when replacing the cables on the battery that the positive cable is attached to the positive post and the negative cable is attached to the negative post. Battery posts are marked (+) positive and negative (-) and identified on the battery case. Also, if a “fast charger” is used while battery is in vehicle, disconnect both vehicle battery cables be- fore connecting the charger to battery. Do not use a “fast charger” to provide starting voltage.
Air Conditioner Maintenance For best possible performance, your air conditioner should be checked and serviced by an Authorized Dealer at the start of each warm season. This service should include cleaning of the condenser fins and a performance test. Drive belt tension should also be checked at this time.
398 MAINTAINING YOUR VEHICLE
WARNING!
† Use only refrigerants and compressor lubricants approved by the manufacturer for your air condi- tioning system. Some unapproved refrigerants are flammable and can explode, injuring you. Other unapproved refrigerants or lubricants can cause the system to fail, requiring costly repairs. † The air conditioning system contains refrigerant under high pressure. To avoid risk of personal injury or damage to the system, adding refrigerant or any repair requiring lines to be disconnected should be done by an experienced repairman.
Refrigerant Recovery and Recycling R-134a Air Conditioning Refrigerant is a hydrofluorocar- bon (HFC) that is endorsed by the Environmental Pro- tection Agency and is an ozone-saving product. How- ever, the manufacturer recommends that air conditioning service be performed by dealers or other service facilities using recovery and recycling equipment. NOTE: Use only manufacturer approved A/C System Sealers, Stop Leak Products, Seal Conditioners, Compres- sor Oil, or Refrigerants. Power Steering — Fluid Check Checking the power steering fluid level at a defined service interval is not required. The fluid should only be checked if a leak is suspected, abnormal noises are apparent, and/or the system is not functioning as antici- pated. Coordinate inspection efforts through a certified DaimlerChrysler Dealership.9
WARNING!
Fluid level should be checked on a level surface and with the engine off to prevent injury from moving parts and to insure accurate fluid level reading. Do not overfill. Use only manufacturers recommended power steering fluid.
If necessary, add fluid to restore to the proper indicated level. With a clean cloth, wipe any spilled fluid from all surfaces. Refer to Fluids, Lubricants, and Genuine Parts for correct fluid type. Front Suspension Ball Joints
NOTE: When anticipating any severe offroad or hill climbing maneuvers, the power steering fluid level may be increased to the FULL HOT level (with a cold system). In this way, the power steering system will continue to
MAINTAINING YOUR VEHICLE 399
provide assist as the inclination angle of the vehicle increases, i.e. when the vehicle is not on level ground. NOTE: When anticipating any severe offroad/dusty or wet conditions, ensure that the outer tie rod ends are properly greased before ans soon after the vehicle is taken through such conditions. The greasing will help purge contaminants and water from under the seal. Regular greasing will prolong the life of the ball joints. The ball joints and seals should be inspected whenever the vehicle is serviced for other reasons. The ball joints originally supplied with the vehicle are permanently lubricated at the factory and do not require service. However, joints are damaged, the joints should be replaced. Serviceable replacement ball joints are available.
if the seals on the ball
400 MAINTAINING YOUR VEHICLE
Front suspension ball joints should be replaced only by a qualified service technician using tools specially de- signed for this purpose. Damage to the joints and/or suspension components may result if improper replace- ment procedures are used. If seals are damaged the ball joints should be replaced to prevent leakage or contamination of the grease. Steering Linkage — Inspection Whenever the vehicle is hoisted, all steering linkage joints should be inspected for evidence of damage. If seals are damaged, parts should be replaced to prevent leakage or contamination of the grease. Lubricate the steering linkage regularly according to the “Maintenance Schedule” in this manual.
Front Prop Shaft Lubrication Lubricate the front driveshaft grease fitting at each oil change listed in the appropriate Maintenance Schedule for your vehicle (Schedule “A” and “B”). Use Mopart type MS-6560 (lithium based grease), or equivalent.
Front Driveshaft Grease Fitting
Body Lubrication Locks and all body pivot points, including such items as seat tracks, doors, tailgate and hood hinges, should be lubricated periodically to assure quiet, easy operation and to protect against rust and wear. Prior to the appli- cation of any lubricant, the parts concerned should be wiped clean to remove dust and grit; after lubricating excess oil and grease should be removed. Particular attention should also be given to hood latching compo- nents to insure proper function. When performing other underhood services, the hood latch, release mechanism and safety catch should be cleaned and lubricated. The external lock cylinders should be lubricated twice a year, preferably in the fall and spring. Apply a small amount of a high quality lubricant such as Mopart Lock Cylinder Lubricant directly into the lock cylinder.
MAINTAINING YOUR VEHICLE 401
Windshield Wiper Blades The rubber edges of the wiper blades and the windshield should be cleaned periodically with a sponge or soft cloth and a mild nonabrasive cleaner. This will remove accu- mulations of salt or road film. Operation of the wipers on dry glass for long periods may cause deterioration of the wiper blades. Always use washer fluid when using the wipers to remove salt or dirt from a dry windshield. Avoid using the wiper blades to remove frost or ice from the windshield. Keep the blade rubber out of contact with petroleum products such as engine oil, gasoline, etc. Windshield Washers The fluid reservoir is located under the hood and should be checked for fluid level at regular intervals. Fill the reservoir with windshield washer solvent only (not ra- diator antifreeze).
402 MAINTAINING YOUR VEHICLE
To prevent freeze-up of your windshield washer system in cold weather, select a solution or mixture that meets or exceeds the temperature range of your climate. This rating information can be found on most washer fluid containers.
WARNING!
Commercially available windshield washer solvents are flammable. They could ignite and burn you. Care must be exercised when filling or working around the washer solution.
After the engine has warmed, operate the defroster for a few minutes to reduce the possibility of smearing or freezing the fluid on the cold windshield. Mopar All Weather Windshield Washer Solution, used with water as
directed on the container, aids cleaning action, reduces the freezing point to avoid line clogging, and is not harmful to paint or trim. Exhaust System The best protection against carbon monoxide entry into the vehicle body is a properly maintained engine exhaust system. Whenever a change is noticed in the sound of the exhaust system, when exhaust fumes can be detected inside the vehicle, or when the underside or rear of the vehicle is damaged, have a competent mechanic inspect the com- plete exhaust system and adjacent body areas for broken, damaged, deteriorated, or mispositioned parts. Open seams or loose connections could permit exhaust fumes to seep into the passenger compartment. In addition, inspect the exhaust system each time the vehicle is raised for lubrication or oil change. Replace as required.
WARNING!
Cooling System
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Exhaust gases can injure or kill. They contain carbon monoxide (CO) which is colorless and odorless. Breathing it can make you unconscious and can eventually poison you. To avoid breathing CO, fol- low the preceding safety tips.
Exhaust System Rubber Isolator and Loop-Type Hanger — If Equipped Inspect surfaces whenever the vehicle is hoisted for rubber to metal separation or deep cracks. SLIGHT CRACKING DUE TO WEATHERING DOES NOT AD- VERSELY AFFECT PERFORMANCE. If, however, exces- sively deep localized cracks are present, or any part of the exhaust system abnormally contacts the underbody hard- ware, the isolator and/or hanger should be replaced.
WARNING!
You or others can be badly burned by hot coolant or steam from your radiator. If you see or hear steam coming from under the hood, don’t open the hood until the radiator has had time to cool. Never try to open a cooling system pressure cap when the radia- tor is hot.
Engine Coolant Checks Check the engine coolant (antifreeze) protection every 12
months (before the onset of freezing weather, where applicable). If coolant is dirty or rusty in appearance, the system should be drained, flushed and refilled with fresh coolant. Check the front of the A/C condenser for any404 MAINTAINING YOUR VEHICLE
accumulation of bugs, leaves, etc. If dirty, clean by gently spraying water from a garden hose vertically down the face of the condenser. Check the coolant recovery bottle tubing for brittle rub- ber, cracking, tears, cuts and tightness of the connection at the bottle and radiator. Inspect the entire system for leaks. With the engine at normal operating temperature (but not running), check the cooling system pressure cap for proper vacuum sealing by draining a small amount of coolant from the radiator drain cock. If the cap is sealing properly, the engine coolant (antifreeze) will begin to drain from the coolant recovery bottle. DO NOT RE- MOVE THE COOLANT PRESSURE CAP WHEN THE COOLING SYSTEM IS HOT.
Cooling System — Drain, Flush and Refill At the intervals shown on the Maintenance Schedules, the system should be drained, flushed and refilled. If the solution is dirty or contains a considerable amount of sediment, clean and flush with a reliable cooling system cleaner. Follow with a thorough rinsing to remove all deposits and chemicals. Properly dispose of old antifreeze solution. Selection Of Coolant Use only the manufacturers recommended coolant, refer to Fluids, Lubricants and Genuine Parts for correct coolant type.
CAUTION!
Mixing of coolants other than specified HOAT en- gine coolants, may result in engine damage and may decrease corrosion protection. If a non-HOAT cool- ant is introduced into the cooling system in an emergency, it should be replaced with the specified coolant as soon as possible. Do not use plain water alone or alcohol base engine coolant (antifreeze) products. Do not use additional rust inhibitors or antirust products, as they may not be compatible with the radiator engine coolant and may plug the radiator. This vehicle has not been designed for use with Propylene Glycol based coolants. Use of Propylene Glycol based coolants is not recommended.
MAINTAINING YOUR VEHICLE 405
Adding Coolant Your vehicle has been built with an improved engine coolant that allows extended maintenance intervals. This coolant can be used up to 5 Years or 100,000 miles before replacement. To prevent reducing this extended mainte- nance period, it is important that you use the same coolant throughout the life of your vehicle. Please review these recommendations for using Hybrid Organic Addi- tive Technology (HOAT) coolant. When adding coolant, a minimum solution of 50% rec- ommended Mopar Antifreeze/ Coolant 5 Year/100,000
Mile Formula HOAT (Hybrid Organic Additive Technol- ogy), or equivalent, in water should be used. Use higher concentrations (not to exceed 70%) if temperatures below 234°F (237°C ) are anticipated. Use only high purity water such as distilled or deionized water when mixing the water/engine coolant solution.406 MAINTAINING YOUR VEHICLE
The use of lower quality water will reduce the amount of corrosion protection in the engine cooling system. Please note that it is the owner’s responsibility to main- tain the proper level of protection against freezing ac- cording to the temperatures occurring in the area where the vehicle is operated. NOTE: Mixing coolant types will decrease the life of the engine coolant and will require more frequent coolant changes. Cooling System Pressure Cap The cap must be fully tightened to prevent loss of coolant, and to insure that coolant will return to the radiator from the coolant recovery bottle. The cap should be inspected and cleaned if there is any accumulation of foreign material on the sealing surfaces.
WARNING!
† The warning words “DO NOT OPEN HOT” on the cooling system pressure cap are a safety pre- caution. Never add coolant when the engine is overheated. Do not loosen or remove the cap to cool an overheated engine. Heat causes pressure to build up in the cooling system. To prevent scalding or injury, do not remove the pressure cap while the system is hot or under pressure. † Do not use a pressure cap other than the one specified for your vehicle. Personal injury or engine damage may result.
Disposal of Used Engine Coolant Used ethylene glycol based engine coolant is a regulated substance requiring proper disposal. Check with your local authorities to determine the disposal rules for your community. To prevent ingestion by animals or children
do not store ethylene glycol based engine coolant in open containers or allow it to remain in puddles on the ground. If ingested by a child, contact a physician immediately. Clean up any ground spills immediately. Coolant Level The coolant bottle provides a quick visual method for determining that the coolant level is adequate. With the engine cold, the level of the coolant in the coolant recovery bottle should be between the ranges indicated on the bottle. The radiator normally remains completely full, so there is no need to remove the radiator cap unless checking for coolant freeze point or replacing coolant. Advise your service attendant of this. As long as the engine operating temperature is satisfactory, the coolant bottle need only be checked once a month.
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When additional coolant is needed to maintain the proper level, it should be added to the coolant bottle. Do not overfill. Points To Remember NOTE: When the vehicle is stopped after a few miles (a few kilometers) of operation, you may observe vapor coming from the front of the engine compartment. This is normally a result of moisture from rain, snow, or high humidity accumulating on the radiator and being vapor- ized when the thermostat opens, allowing hot coolant to enter the radiator. If an examination of your engine compartment shows no evidence of radiator or hose leaks, the vehicle may be safely driven. The vapor will soon dissipate. † Do not overfill the coolant recovery bottle.
408 MAINTAINING YOUR VEHICLE
† Check coolant freeze point in the radiator and in the coolant recovery bottle. If antifreeze needs to be added, contents of coolant recovery bottle must also be protected against freezing. † If frequent coolant additions are required, or if the level in the coolant recovery bottle does not drop when the engine cools, the cooling system should be pres- sure tested for leaks. † Maintain coolant concentration at 50% HOAT engine coolant (minimum) and distilled water for proper corrosion protection of your engine which contains aluminum components. † Make sure that the radiator and coolant recovery bottle overflow hoses are not kinked or obstructed. † Keep the front of the radiator clean. If your vehicle is equipped with air conditioning, keep the front of the condenser clean, also.
† Do not change the thermostat for summer or winter operation. If replacement is ever necessary, install ONLY the correct type thermostat. Other designs may result in unsatisfactory coolant performance, poor gas mileage, and increased emissions.
Hoses And Vacuum/Vapor Harnesses Inspect surfaces of hoses and nylon tubing for evidence of heat and mechanical damage. Hard or soft spots, brittle rubber, cracking, tears, cuts, abrasions, and exces- sive swelling indicate deterioration of the rubber. Pay particular attention to those hoses nearest to high heat sources such as the exhaust manifold. Inspect hose routing to be sure hoses do not come in contact with any heat source or moving component which may cause heat damage or mechanical wear. Insure nylon tubing in these areas has not melted or collapsed.
Inspect all hose connections such as clamps and cou- plings to make sure they are secure and no leaks are present. Components should be replaced immediately if there is any evidence of wear or damage that could cause failure. Brake System
Power Disc Brakes (front and rear) Disc brakes do not require adjustment; however, several hard stops during the break-in period are recommended to seat the linings and wear off any foreign material. Brake Master Cylinder The fluid level of the master cylinder should be checked when performing under the hood service, or immedi- ately if the brake system warning lamp indicates system failure. The brake master cylinder has a translucent plastic reservoir. On the outboard side of the reservoir, there is a
MAINTAINING YOUR VEHICLE 409
“MAX” dot and an “MIN” dot. The fluid level must be kept within these two dots. Do not add fluid above the MAX mark, because leakage may occur at the cap. With disc brakes the fluid level can be expected to fall as the brake linings wear. However, an unexpected drop in fluid level may be caused by a leak and a system check should be conducted. Refer to Fluids, Lubricants and Genuine Parts for the correct Fluid type.
WARNING!
Use of a brake fluid that may have a lower initial boiling point, or is unidentified as to specification, may result in sudden brake failure during hard prolonged braking. You could have an accident.
410 MAINTAINING YOUR VEHICLE
WARNING!
Overfilling the brake fluid reservoir can result in spilling brake fluid on hot engine parts and the brake fluid catching fire.
Use only brake fluid that has been in a tightly closed container to avoid contamination from foreign matter or moisture.
CAUTION!
Do not allow a petroleum-base fluid to contaminate the brake fluid. Seal damage may result.
Brake Hoses Inspection should be performed whenever the brake system is serviced or at intervals specified. Inspect hy- draulic brake hoses for surface cracking, scuffing or worn spots. If there is any evidence of cracking, scuffing, or worn spots, the hose should be replaced immediately! Eventual deterioration of the hose can take place with possible burst failure. Clutch Hydraulic System
The clutch hydraulic system is a sealed maintenance-free system. In the event of leakage or other malfunction, the system must be replaced. Clutch Linkage If the clutch pedal linkage begins to squeak or grunt, the clutch pedal pivot bushings should be lubricated. Refer to Fluids, Lubricants and Genuine Parts for the correct lubricant type.
Rear Axle And 4x4 Front Driving Axle Fluid Level Refer to Fluids, Lubricants and Genuine Parts for the correct Fluid type. For normal service, periodic fluid level checks are not required. When the vehicle is serviced for other reasons the exterior surfaces of the axle assembly should be inspected. If gear oil leakage is suspected inspect the fluid level. This inspection should be made with the vehicle in a level position. The fluid level should be even with the bottom of the fill hole for the Manufacturer’s C205F HD Front Axles. The fluid level should be 5/8” (16 mm) below on 9 1/4” Manufacturer’s Rear Axles. For all 2500 Model axles, the fluid level should be 1/4” ± 1/4” (6.4 mm ± 6.4 mm) below the fill hole on the 9.25” Front and 3/4”± 1/4” (19 mm ± 6.4 mm) on 10.5” Rear axles.
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Drain and Refill Vehicles operated in normal service do not have regularly scheduled oil changes. If fluid has become contaminated with water or to provide the correct viscosity grade, drain and refill. Lubricant Selection Refer to Fluids, Lubricants and Genuine Parts for correct fluid type. NOTE: The presence of water in the gear lubricant will result in corrosion and possible failure of differential components. Operation of the vehicle in water, as may be encountered in some off-highway types of service, will require draining and refilling the axle to avoid damage. Limited-Slip Differentials Power Wagon Axles DO NOT REQUIRE any limited slip oil additive (friction modifiers).
412 MAINTAINING YOUR VEHICLE
Transfer Case
Fluid Level Check This fluid level can be checked by removing the filler plug. The fluid level should be to the bottom edge of the filler plug hole with the vehicle in a level position. Lubricant Selection Refer to Fluids, Lubricants and Genuine Parts for correct fluid type. Front Drive Shaft The front drive shaft contains a grease fitting which should be serviced at every oil change (see maintenance schedule A/B). Manual Transmission
Fluid Level Check This fluid level can be checked by removing the filler plug. If the level of the lubricant is more than 1/4” (6.4
mm) below the bottom of the filler hole while the vehicleis on level ground, enough lubricant should be added to bring the level to the bottom of the filler hole. Lubricant Selection G56 (6 – Speed Manual Transmission — If Equipped) This transmission does not require periodic changing. If it becomes necessary to add or change the fluid in this transmission, refer to Fluids, Lubricants and Genuine Parts for correct fluid type. Automatic Transmission
Fluid Level Check The fluid level should be checked when the engine is fully warmed up and the fluid in the transmission is at normal operating temperature. Operation of the trans- mission with an improper fluid level will greatly reduce the life of the transmission and of the fluid. Check the fluid level whenever the vehicle is serviced.
Fluid Level Check – 545RFE Check the fluid level while the transmission is at normal operating temperature 82°C (180°F). This occurs after at least 15 miles (25 km) of driving. At normal operating temperature the fluid cannot be held comfortably be- tween the fingertips. To check the automatic transmission fluid level properly, the following procedure must be used: 1. Operate the engine at idle speed and normal operating temperature. 2. The vehicle must be on level ground. 3. Fully apply the parking brake and press the brake pedal. 4. Place the gear selector momentarily in each gear position ending with the lever in P (Park).
MAINTAINING YOUR VEHICLE 413
5. Remove the dipstick, wipe it clean and reinsert it until seated. 6. Remove the dipstick again and note the fluid level on both sides. The fluid level should be between the “HOT” (upper) reference holes on the dipstick at normal operat- ing temperature. Verify that solid coating of oil is seen on both sides of the dipstick. If the fluid is low, add as required into the dipstick tube. Do not overfill. After adding any quantity of oil through the oil fill tube, wait a minimum of two (2) minutes for the oil to fully drain into the transmission before rechecking the fluid level. If it is necessary to check the transmission below NOTE: the operating temperature, the fluid level should be between the two “COLD” (lower) holes on the dipstick with the fluid at approximately 70°F (21°C) (room tem- perature). If the fluid level is correctly established at it should be between the “HOT” room temperature,
414 MAINTAINING YOUR VEHICLE
(upper) reference holes when the transmission reaches 180°F (82°C). Remember it is best to check the level at the normal operating temperature.
CAUTION!
Be aware that if the fluid temperature is below 50°F (10°C) it may not register on the dipstick. Do not add fluid until the temperature is elevated enough to produce an accurate reading.
7. Check for leaks. Release parking brake. To prevent dirt and water from entering the transmission after checking or replenishing fluid, make certain that the dipstick cap is properly reseated. It is normal for the dipstick cap to spring back slightly from its fully seated position, as long as its seal remains engaged in the dipstick tube.
Selection Of Lubricant Refer to Fluids, Lubricants and Genuine Parts for correct fluid type. It is important that the transmission fluid be maintained at the prescribed level using the recom- mended fluid.
CAUTION!
Using a transmission fluid other than the manufac- turers recommended fluid may cause deterioration in transmission shift quality and/or torque converter shudder. Using a transmission fluid other than the manufacturers recommended fluid will result in more frequent fluid and filter changes. Refer to Fluids, Lubricants and Genuine Parts for correct fluid type.
Automatic Transmission Fluid and Filter Change To obtain best performance and long life for automatic transmissions, the manufacturer recommends that they be given regular maintenance service by an Authorized Dodge Dealer or Service Center. It is important that proper lubricant is used in the transmission. Refer to Fluids, Lubricants and Genuine Parts for correct fluid type. The fluid and filter(s) should be changed as specified in the Maintenance Schedule (Section 8). NOTE: reason, the fluid and filter(s) should be changed. Special Additives The manufacturer strongly recommends against the ad- dition of any additives to the transmission. Exception to this policy is the use of special dyes to aid in detecting
If the transmission is disassembled for any
MAINTAINING YOUR VEHICLE 415
In some instances,
fluid leaks. The use of transmission sealers should be avoided, since they may adversely affect seals. Front Wheel Bearings Front wheel bearings for all Dodge Ram Trucks are sealed-for-life. They do not require greasing or seal replacement. these bearings will “purge” excess grease and the bearing will look slightly wet. This is normal. Periodic inspection for excess play is recommended. Rear Wheel Bearings — Manufacturer’s Axles These bearings are normally considered permanently lubricated. Cleaning and repacking is required only when axle shafts are removed or in case of extreme water or dust contamination.
416 MAINTAINING YOUR VEHICLE
Selection of Lubricating Grease The National Lubricating Grease Institute (NLGI) has developed a symbol (Certification Mark) to aid the vehicle owner in the proper selection of grease for the lubrication of wheel bearings and chassis components. This symbol (an example is shown below) is located on the grease container and identifies the application and quality of the grease.
are
There two groups identified, those for wheel bearings (Letter “G”) and those for chassis (Letter “L”) lubrication. Perfor- mance categories within these groups result in dual letter for each group. The letter des- ignations shown in the ex- ample the highest
designations
are
quality level available and when combined as shown can be used for both wheel bearing and chassis lubrication. Use only those greases that have the NLGI symbol on the container along with the proper quality level for your application. Noise Control System Required Maintenance & Warranty All vehicles built over 10,000 lbs (4 535 kg) Gross Vehicle Weight Rating and manufactured for sale and use in the United States are required to comply with the Federal Government’s Exterior Noise Regulations. These vehicles
can be identified by the Noise Emission Control Label located in the operator’s compartment.
MAINTAINING YOUR VEHICLE 417
In addition,
Required Maintenance for Noise Control Systems The following maintenance services must be performed every 6 months or 6,000 miles (9 600 km), whichever comes first, to assure proper operation of the noise control systems. inspection and service should be performed anytime a malfunction is observed or suspected. Proper maintenance of the entire vehicle will help the effectiveness of the noise control systems. Air Cleaner Assembly Inspect air cleaner housing for proper assembly and fit. Make certain that the air cleaner is properly positioned and the cover is tight. Check all hoses leading to the cleaner for tightness. The gasket between the air cleaner housing and throttle body must be intact and in good condition. The engine air cleaner filter must also be clean and serviced according to the instructions outlined in the appropriate maintenance schedule.
418 MAINTAINING YOUR VEHICLE
Tampering with Noise Control System Prohibited Federal law prohibits the following acts or the causing thereof: (1) the removal or rendering inoperative by any person, other than for purposes of maintenance, repair, or replacement, of any device or element of design incorpo- rated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. Among those acts presumed to constitute tampering are the acts listed below. AIR CLEANER † Removal of the air cleaner. † Inverting the air cleaner lid. † Removal of the air ducting.
EXHAUST SYSTEM † Removal or rendering inoperative exhaust system
components including the muffler or tailpipe.
ENGINE COOLING SYSTEM † Removal or rendering inoperative the fan clutch. † Removal of the fan shroud. Noise Emission Warranty The manufacturer warrants that this vehicle as manufac- tured by the manufacturer, was designed, built and equipped to conform at the time it left the manufacturers control with all applicable U.S. EPA Noise Control Regu- lations. This warranty covers this vehicle as designed, built and equipped by the manufacturer, and is not limited to any particular part, component or system of the vehicle manufactured by the manufacturer. Defects in design,
MAINTAINING YOUR VEHICLE 419
6,000
9 600emissions to exceed Federal standards, are covered by this warranty for the life of the vehicle.
assembly or in any part, component or system of the vehicle as manufactured by the manufacturer, which, at the time it left the manufacturers control, caused noise Noise Systems Maintenance Chart and Service Log Insert Month, Day, Year under column mileage closest to the mileage at which service was performed. MILES KILOMETERS Exhaust system- inspect Air cleaner assembly-inspect ODOMETER READING PERFORMED BY PERFORMED AT
18,000
29 00024,000
36 00030,000
48 00036,000
58 00042,000
67 00012,000
19 00048,000
77 000420 MAINTAINING YOUR VEHICLE
60,000
96 00054,000
87 00072,000
116 00066,000
106 000Noise Systems Maintenance Chart and Service Log Insert Month, Day, Year under column mileage closest to the mileage at which service was performed. MILES KILOMETERS Exhaust system- inspect Air cleaner assembly-inspect ODOMETER READING PERFORMED BY PERFORMED AT Appearance Care and Protection from Corrosion
78,000
126 00096,000
154 00084,000
135 00090,000
145 000Protection of Body and Paint from Corrosion Vehicle body care requirements vary according to geo- graphic locations and usage. Chemicals that make roads passable in snow and ice, and those that are sprayed on trees and road surfaces during other seasons, are highly
corrosive to the metal in your vehicle. Outside parking, which exposes your vehicle to airborne contaminants, road surfaces on which the vehicle is operated, extreme hot or cold weather and other extreme conditions will have an adverse effect on paint, metal trim, and under- body protection.
The following maintenance recommendations will enable you to obtain maximum benefit from the corrosion resistance built into your vehicle. What Causes Corrosion? Corrosion is the result of deterioration or removal of paint and protective coatings from your vehicle. The most common causes are: † Road salt, dirt and moisture accumulation. † Stone and gravel impact. † Insects, tree sap and tar. † Salt in the air near seacoast localities. † Atmospheric fallout/industrial pollutants.
MAINTAINING YOUR VEHICLE 421
Washing † Wash your vehicle regularly. Always wash your ve- hicle in the shade using Mopart Car Wash or a mild car wash soap, and rinse the panels completely with clear water. † If insects, tar or other similar deposits have accumu- lated on your vehicle, use Mopart Super Kleen Bug and Tar Remover to remove. † Use Mopart Cleaner Wax to remove road film, stains and to protect your paint finish. Take care never to scratch the paint. † Avoid using abrasive compounds and power buffing that may diminish the gloss or thin out the paint finish.
422 MAINTAINING YOUR VEHICLE
CAUTION!
Do not use abrasive or strong cleaning materials such as steel wool or scouring powder, which will scratch metal and painted surfaces.
Special Care † If you drive on salted or dusty roads or if you drive near the ocean, hose off the undercarriage at least once a month. † It is important that the drain holes in the lower edges of the doors, rocker panels and trunk be kept clear and open. † If you detect any stone chips or scratches in the paint, touch them up immediately. The cost of such repairs is considered the responsibility of the owner.
† If your vehicle is damaged due to an accident or similar cause which destroys the paint and protective coating, have your vehicle repaired as soon as pos- sible. The cost of such repairs is considered the respon- sibility of the owner. † If you carry special cargo such as chemicals, fertilizers, de-icer salt, etc., be sure that such materials are well packaged and sealed. † If a lot of driving is done on gravel roads, consider † Use Mopart touch up paint on scratches as soon as possible. Your dealer has touch up paint to match the color of your vehicle.
mud or stone shields behind each wheel.
Wheel and Wheel Trim Care All wheels and wheel trim, especially aluminum and chrome plated wheels should be cleaned regularly with a mild soap and water to prevent corrosion. To remove
heavy soil, use Mopart Wheel Cleaner or select a non- abrasive, non-acidic cleaner. Do not use scouring pads, steel wool, a bristle brush or metal polishes. Only Mo- part cleaners are recommended. Do not use oven cleaner. Avoid automatic car washes that use acidic solutions or harsh brushes that may damage the wheels’ protective finish. YES Essentialst Fabric Cleaning Procedure – If equipped YES Essentialst seats may be cleaned in the following manner: † Remove as much of the stain as possible by blotting † Blot any remaining stain with a clean, damp towel. † For tough stains, apply Mopart Total Clean or a mild soap solution to a clean, damp cloth and remove stain. Use a fresh, damp towel to remove soap residue.
with a clean, dry towel.
MAINTAINING YOUR VEHICLE 423
† For grease stains, apply Mopart Multi-purpose cleaner to a clean, damp cloth and remove stain. Use a fresh, damp towel to remove soap residue. † Do not use any solvents or protectants on Yes Essen-
tials products.
Interior Care Use Mopart Total Clean to clean fabric upholstery and carpeting. Use Mopart Total Clean to clean vinyl upholstery. Mopart Total Clean is specifically recommended for leather upholstery. Your leather upholstery can be best preserved by regular cleaning with a damp soft cloth. Small particles of dirt can act as an abrasive and damage the leather upholstery and should be removed promptly with a damp cloth. Stubborn soils can be removed easily with a soft cloth and Mopart Total Clean. Care should be taken to avoid
424 MAINTAINING YOUR VEHICLE
soaking your leather upholstery with any liquid. Please do not use polishes, oils, cleaning fluids, solvents, deter- gents, or ammonia based cleaners to clean your leather upholstery. Application of a leather conditioner is not required to maintain the original condition.
WARNING!
Do not use volatile solvents for cleaning purposes. Many are potentially flammable, and if used in closed areas they may cause respiratory harm.
Glass Surfaces All glass surfaces should be cleaned on a regular basis with Mopart Glass Cleaner or any commercial household-type glass cleaner. Never use an abrasive type cleaner. Use caution when cleaning the inside rear win- dow equipped with electric defrosters or the right rear quarter window equipped with the radio antenna. Do
not use scrapers or other sharp instruments which may scratch the elements. When cleaning the rear view mirror, spray cleaner on the towel or rag that you are using. Do not spray cleaner directly on the mirror. Cleaning Plastic Instrument Cluster Lenses The lenses in front of the instruments in this vehicle are molded in clear plastic. When cleaning the lenses, care must be taken to avoid scratching the plastic. 1. Clean with a wet soft rag. A mild soap solution may be used, but do not use high alcohol content or abrasive cleaners. If soap is used, wipe clean with a clean damp rag. 2. Dry with a soft tissue. Seat Belt Maintenance Do not bleach, dye or clean the belts with chemical solvents or abrasive cleaners. This will weaken the fabric. Sun damage can also weaken the fabric.
If the belts need cleaning, use a mild soap solution or lukewarm water. Do not remove the belts from the car to wash them. Replace the belts if they appear frayed or worn or if the buckles do not work properly. Dry with a soft tissue.
FUSES (INTEGRATED POWER MODULE) An integrated Power Module is located in the engine compartment near the battery. This center contains car- tridge fuses and mini fuses. A description of each fuse and component may be stamped on the inside cover otherwise the cavity number of each fuse is stamped on the inside cover that corresponds to the following chart.
MAINTAINING YOUR VEHICLE 425
Integrated Power Module Location
426 MAINTAINING YOUR VEHICLE
Cavity Cartridge
Fuse
Mini Fuse 20 Amp Yellow 20 Amp Yellow
20 Amp Yellow 15 Amp Blue 20 Amp Yellow 10 Amp Red
Description
Power Outlet Console
Cabin Compartment Node (CCN) Door Locks/Brake Trans- mission Shift Inter- lock (BTSI) Spare
Spare
Power Sunroof
VIST Fan/Wastegate
Cavity Cartridge
Fuse
10
30 Amp Pink
Mini Fuse 15 Amp Blue
10 Amp Red
5 Amp Orange
Description
Reverse Lockout Sole- noid Battery (SRT-10
Only) Heated MirrorsOff Road Module Power Trx-Off Rd Pkg Sen (Gas Engine Only)
Cavity Cartridge
Fuse
11
12
13
14
30 Amp Pink
Mini Fuse 20 Amp Yellow
25 Amp Natural
15 Amp Blue
Description
Cavity Cartridge
Fuse
Ignition Off Draw (IOD)-Cabin Com- partment Node (CCN)/Radio/Under Hood Lamp/Wireless Control Module (WCM)/Satellite Digi- tal Audio Receiver (SDARS)/Hands Free Module (HFM) Electric Brake
Power-Battery RWAL/ABS Module Feed Park Lamps Left
15
16
17
18
19
20
21
22
40 Amp Green 30 Amp Pink
MAINTAINING YOUR VEHICLE 427
Mini Fuse 20 Amp Yellow 15 Amp Blue 15 Amp Blue
10 Amp Red 10 Amp Red
2 Amp Gray
Description
Trailer Park Lamps
Park Lamps Right
Spare
ABS Pump
Trailer Tow
Occupant Restraints Controller (ORC) 2
Occupant Restraints Controller (ORC) Pre- set Carrier IGN Switch Feed428 MAINTAINING YOUR VEHICLE
Cavity Cartridge
Fuse
23
24
25
26
27
28
20 Amp Blue
40 Amp Green
Mini Fuse 10 Amp Red
10 Amp Red 20 Amp Yellow
10 Amp Red
Description
Engine Control Mod- ule (ECM)/Wireless Control Module (WCM)/HVC Subwoofer Amplifier (SRT-10 Only) Power Mirror
Brake Switch/Center High Mount Stop Lamp (CHMSL) Power Seats
Power Run/Start- NCC/Wireless Con- trol Module (WCM)/ ABS/RWAL
Cavity Cartridge
Fuse
29
30
31
32
33
34
35
Mini Fuse 10 Amp Red 15 Amp Blue 10 Amp Red 10 Amp Red
10 Amp Red 10 Amp Red 15 Amp Blue
Description
Switches/EC Mirror/ Smart Bar Spare
PCM/Transfer Case Brake HVAC/Ajustable Pedals/Heated Seats Switch LED/Exhaust Brake Power-IGN Run Misc
Spare
Cabin Compartment Node (CCN) Illumi- nation
Cavity Cartridge
Fuse
Mini Fuse 25 Amp Natural 15 Amp Blue 20 Amp Yellow 10 Amp Red 20 Amp Yellow 25 Amp Natural
Description
Audio_Amplifier
Spare
Power Outlet IP
Sunroof/Seatbelt Ten- sioner Cigar Lighter
Spare
30 Amp Pink
Diesel PCM (Diesel Only)
36
37
38
39
40
41
42
MAINTAINING YOUR VEHICLE 429
CAUTION!
† When installing the Integrated Power Module cover, it is important to ensure the cover is prop- erly positioned and fully latched. Failure to do so may allow water to get into the Integrated Power Module, and possibly result in a electrical system failure. † When replacing a blown fuse, it is important to use only a fuse having the correct amperage rating. The use of a fuse with a rating other than indicated may result in a dangerous electrical system overload. If a properly rated fuse contin- ues to blow, it indicates a problem in the circuit that must be corrected.
430 MAINTAINING YOUR VEHICLE
VEHICLE STORAGE If you are storing your vehicle for more than 21 days, we recommend that you take the following steps to mini- mize the drain on your vehicle’s battery: † Disconnect the Ignition-Off Draw fuse (I.O.D.) fuse located in the Integrated Power Module, located in the engine compartment. The I.O.D. cavity includes a snap-in retainer that allows the fuse to be discon- nected, without removing it from the fuse block. † The electronic shift transfer case should be placed in the 4HI mode and kept in this position to minimize the battery drain. † As an alternative to the above steps you may, discon- † Anytime you store your vehicle, or keep it out of service (i.e. vacation) for two weeks or more, run the air conditioning system at idle for about five minutes
nect the negative cables from both batteries.
in the fresh air and high blower setting. This will insure adequate system lubrication to minimize the possibility of compressor damage when the system is started again.
NOTE: When reinstalling the IOD fuse push firmly until fully seated, the gages in the Instrument Cluster will do a full sweep, when the ignition key is cycled to RUN. This is a normal condition.
REPLACEMENT LIGHT BULBS
LIGHT BULBS — Inside Bulb No. Overhead Console Lights . . . . . . . . . . . . . . . TS 212-2
Dome Light. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7679
All of the inside bulbs are brass or glass wedge base. Aluminum base bulbs are not approved.LIGHT BULBS — Outside Bulb No. Back-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3057
Center High Mounted Stop Lamp . . . . . . . . . . . . . 912
Fog Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . 9006LL Headlamp (Halogen) . . . . . . . . . . . . . . . . . . . . . H13
Side Marker, Park & Turn Signal . . . . . . . . . 3157NAK Rear License Plate Lamp . . . . . . . . . . . . . . . . . . . 168
Rear Cargo Light. . . . . . . . . . . . . . . . . . . . . . . . . 912
Tail & Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3057BULB REPLACEMENT
Headlight (Halogen)/Front Park and Turn Lights
CAUTION!
MAINTAINING YOUR VEHICLE 431
1. Open the hood 2. Remove the two (2) bolts from the front of the head- light housing.
This is a halogen bulb. Avoid touching the glass with your fingers. Reduced bulb life will result.
Front Headlight Housing Bolts
432 MAINTAINING YOUR VEHICLE
3. Remove the plug from the inner fender well and remove the nut through the access hole.
Inner Fender Plug
Rear Headlight Housing Nut Access
4. Pull the housing out from the fender to allow room to disconnect the electrical connectors. NOTE: For easier removal, pull the headlight assembly straight forward, applying the greatest amount of force to the outer edge of the headlight assembly.
MAINTAINING YOUR VEHICLE 433
Headlight Removal
Bulb Removal
5. Unlock and pull connector straight from the base of the headlight halogen bulb. 6. Twist connector on the side marker/turn signal/park light bulb 1⁄4 turn and remove connector and bulb from housing.
434 MAINTAINING YOUR VEHICLE
7. Remove housing from vehicle with headlight halogen bulb in housing. 8. Twist the headlight halogen bulb 1⁄4 turn and remove headlight bulb from the housing. 9. Replace headlight or side marker/turn signal/park light bulb. Do not touch the headlight halogen bulb. 10. Reverse procedure for installation of bulbs and hous- ing.
Tail, Stop, Turn and Backup Lights
1. Remove the two (2) screws that pass through the bed sheetmetal.
Removing the Two (2) Screws
2. Pull the housing straight out from the body, with a quick motion, to separate the housing from the body. If not pulled straight, locators may be damaged.
MAINTAINING YOUR VEHICLE 435
3. Rotate the bulb socket counterclockwise to remove from the housing.
Pulling Housing From Body
Rotating Bulb Socket From Housing
436 MAINTAINING YOUR VEHICLE
4. Pull bulb straight out of socket.
5. Reverse Procedure to install bulb and housing. Place the two raised blocks passed the body.
Pulling Bulb From Socket
Sliding Raised Blocks Past Body
Center High-Mounted Stoplight With Cargo Light
1. Remove the two (2) screws holding the housing/lens to the body as shown.
MAINTAINING YOUR VEHICLE 437
2. Separate the connector holding the housing and wir- ing harness to the body.
3. Turn desired bulb socket 1⁄4 turn and remove socket and bulb from housing.
438 MAINTAINING YOUR VEHICLE
4. Pull desired bulb straight from the socket.
Cab Top Clearance Lights — If Equipped
1. Remove the two screws from the top of the light.
† Outside Bulbs: Cargo Lamps † Inside Bulb: Center High Mount Stop Lamp 5. Reverse procedure for installation of bulbs and hous- ing.
2. Rotate the socket 1⁄4 turn and pull it from the light assembly.
3. Pull the bulb straight from it’s socket and replace.
MAINTAINING YOUR VEHICLE 439
440 MAINTAINING YOUR VEHICLE
Fog Lights
1. Reach under the vehicle, unlock and twist connector counterclockwise 1⁄4 turn and remove connector and bulb from housing.
3. Reverse procedure for installation of bulbs and hous- ing.
2. Pull bulb straight from the connector.
FLUIDS AND CAPACITIES
Fuel
5.7L, 89 Octane
2500 Shortbed Models 2500 Longbed Models
Engine Oil (with filter) 5.7L Engine V-8 (SAE 5W-20, API Certified). For trucks operating under a gross combined weight rating less
than 14,000 lbs.
5.7L Engine V-8 (SAE 5W-30, API Certified). For trucks
operating under a gross combined weight rating
greater than 14,000 lbs.
Cooling System 5.7L (Mopart Antifreeze/Coolant 5 Year/100,000 Mile
Formula)
MAINTAINING YOUR VEHICLE 441
Metric
128L 132L
6.6L
6.6L
17.7L
U.S.
34 gal. 35 gal.
7.0 qts.
7.0 qts.
18.7 qts.
442 MAINTAINING YOUR VEHICLE
FLUIDS, LUBRICANTS AND GENUINE PARTS Engine Component Engine Coolant
Engine Oil (For trucks operating under a gross combined weight rating less than 14,000 lbs.) 5.7L Engine Oil (For trucks operat- ing under a gross combined weight rating greater than 14,000
lbs.) Engine Oil Filter Spark PlugsFuel Selection (5.7L)
Fluids, Lubricants and Genuine Parts Mopart Antifreeze/Coolant 5 Year/100,000 Mile Formula HOAT (Hybrid Or- ganic Additive Technology) P/N 5011764AB or equivalent. Use SAE 5W-20, API Certified, meeting material standard MS-6395.
Use SAE 5W-30, API Certified, meeting material standard MS-6395.
Mopart Engine Oil Filter, P/N 5281090 or equivalent. Refer to the Vehicle Emission Control Information label in the engine com- partment. 89 Octane Mid-Grade, (R+M)/2 Method Preferred (87 Octane Acceptable)
MAINTAINING YOUR VEHICLE 443
Chassis Component Automatic Transmission Transfer Case Manual Transmission Fluid (G-56) Front Driveshaft Grease Fitting. Clutch Linkage Front and Rear Axle
Brake Master Cylinder
Power Steering Reservoir
Fluids, Lubricants and Genuine Parts. Mopart ATF+4, Automatic Transmission Fluid Mopart ATF+4, Automatic Transmission Fluid Mopart ATF+4, Automatic Transmission Fluid Use Mopart type MS-6560 (lithium based grease), or equivalent. Multipurpose Grease, NLGI Grade 2 E.P. Synthetic, GL-5 SAE, 75W-90. Limited-Slip 10.5 inch Rear Axle DOES NOT REQUIRE a limited slip additive. Mopart DOT 3 and SAE J1703 should be used. If DOT 3 brake fluid is not available, then DOT 4 is acceptable. Use only recommended brake fluids. Mopart ATF+4, Automatic Transmission Fluid
MAINTENANCE SCHEDULES
CONTENTS
m Emission Control System Maintenance . . . . . . . . 446
m Maintenance Schedules . . . . . . . . . . . . . . . . . . . 446N Schedule “B” . . . . . . . . . . . . . . . . . . . . . . . . 449
N Schedule “A” . . . . . . . . . . . . . . . . . . . . . . . . 460M
446 MAINTENANCE SCHEDULES
EMISSION CONTROL SYSTEM MAINTENANCE The “Scheduled” maintenance services, listed in bold type in this section (Section 8) must be done at the times or mileages specified to assure the continued proper functioning of the emission control system. These, and all other maintenance services included in this manual, should be done to provide best vehicle performance and reliability. More frequent maintenance may be needed for vehicles in severe operating conditions such as dusty areas and very short trip driving. Inspection and service also should be done any time a malfunction is suspected. NOTE: Maintenance, replacement, or repair of the emis- sion control devices and systems on your vehicle may be performed by any automotive repair establishment or individual using any automotive part which has been certified pursuant to U.S. EPA or, in the State of Califor- nia, California Air Resources Board regulations.
MAINTENANCE SCHEDULES There are two maintenance schedules that show the required service for your vehicle. First is Schedule “B”. It is for vehicles that are operated under the conditions that are listed below and at the beginning of the schedule. † Day or night temperatures are below 32° F (0° C). † Stop and go driving. † Extensive engine idling. † Driving in dusty conditions. † Short trips of less than 10 miles (16 km). † More than 50% of your driving is at sustained high † Trailer towing. † Snowplowing.
speeds during hot weather, above 90° F C (32°).
† Heavy Loading. † Taxi, police, or delivery service (commercial service). † Off-road or desert operation. † If equipped for and operating with E-85 (ethanol)
fuel.
If ANY of these apply to you then change your NOTE: engine oil every 3,000 miles (5 000 km) or 3 months, whichever comes first and follow schedule “B” of the 9Maintenance Schedules9 section of this manual. If ANY of these apply to you then flush and NOTE: replace your engine coolant every 102,000 miles (170 000
km) or 60 months, whichever comes first and follow schedule “B” of the 9Maintenance Schedules9 section of this manual. NOTE: Most vehicles are operated under the conditions listed for Schedule 9B9.MAINTENANCE SCHEDULES 447
Second is Schedule “A”. It is for vehicles that are not operated under any of the conditions listed under Sched- ule 9B9. Use the schedule that best describes your driving condi- tions. Where time and mileage are listed, follow the interval that occurs first. NOTE: Under no circumstances should oil change in- tervals exceed 6000 miles (10 000 km) or 6 months whichever comes first.
CAUTION!
Failure to perform the required maintenance items may result in damage to the vehicle.
M
448 MAINTENANCE SCHEDULES
At Each Stop for Fuel † Check the engine oil level about 5 minutes after a fully warmed engine is shut off. Checking the oil level while the vehicle is on level ground will improve the accu- racy of the oil level reading. Add oil only when the level is at or below the ADD or MIN mark. † Check the windshield washer solvent and add if
required.
damage.
Once a Month † Check tire pressure and look for unusual wear or † Inspect the battery and clean and tighten the terminals † Check the fluid levels of coolant bottle, brake master
as required.
cylinder, and transmission and add as needed.
† Check all lights and all other electrical items for correct
operation.
end links.
At Each Oil Change † Change the engine oil filter. † Lubricate the front driveshaft grease fitting and tie rod † Inspect the exhaust system. † Inspect the brake hoses. † Inspect the U—joints and front suspension compo- † Check the automatic transmission fluid level. † Check the manual transmission fluid level. † Check the coolant level, hoses, and clamps. † Lubricate Front Drive Shaft Fitting.
nents.
Schedule “B” Follow schedule “B” if you usually operate your vehicle under one or more of the following conditions. † Day or night temperatures are below 32° F (0° C). † Stop and go driving. † Extensive engine idling. † Driving in dusty conditions. † Short trips of less than 10 miles (16 km). † More than 50% of your driving is at sustained high † Trailer towing. † Snowplowing. † Heavy Loading. † Taxi, police, or delivery service (commercial service).
speeds during hot weather, above 90° F C (32°).
† Off-road or desert operation. † If equipped for and operating with E-85 (ethanol)
SCHEDULE “B” 449
fuel.
If ANY of these apply to you then change your NOTE: engine oil every 3,000 miles (5 000 km) or 3 months, whichever comes first and follow schedule “B” of the 9Maintenance Schedules9 section of this manual. If ANY of these apply to you then flush and NOTE: replace your engine coolant every 102,000 miles (170 000
km) or 60 months, whichever comes first and follow schedule “B” of the 9Maintenance Schedules9 section of this manual. If none of these apply to you, then change your engine oil at every interval shown on schedule 9A9 of the 9Mainte- nance Schedules9 section of this manual.M
