2010 Dodge RAM Diesel Owners Manual

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2 0 1 0 OWNE R ’ S MANUAL Ram Truck Diesel Supplement SECTION TABLE OF CONTENTS PAGE INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 UNDERSTANDING YOUR INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 STARTING AND OPERATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 WHAT TO DO IN EMERGENCIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 MAINTAINING YOUR VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 MAINTENANCE SCHEDULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 INTRODUCTION CONTENTS 䡵 A Message From Chrysler Group LLC . . . . . . . . . 4 4 INTRODUCTION A MESSAGE FROM CHRYSLER GROUP LLC Chrysler Group LLC and Cummins威 welcome you as a Cummins威 turbocharged diesel-powered truck owner. Your diesel truck will sound, feel, drive, and operate differently from a gasoline-powered truck. It is important that you read and understand this manual. Almost 100% of the heavy duty trucks in the United States and Canada are diesel-powered because of the fuel economy, rugged durability, and high torque which per- mits pulling heavy loads. Cummins威 engines power well over half of these trucks. Now this same technology and proven performance is yours in your truck equipped with the Cummins威 turbocharged diesel engine. You may find that some of the starting, operating, and maintenance procedures are different. However, they are simple to follow and careful adherence to them will ensure that you take full advantage of the features of this engine. NOTE: Some aftermarket products may cause severe engine/transmission and/or exhaust system damage. Your vehicle’s Powertrain Control Systems can detect and store information about vehicle modifications that increase horsepower and torque output such as whether or not performance-enhancing powertrain components, commonly referred to as downloaders, power boxes, or performance chips have been used. This information cannot be erased and will stay in the system’s memory even if the modification is removed. This information can be retrieved by Chrysler Group LLC, and service and repair facilities, when servicing your vehicle. This information may be used to determine if repair will be covered by warranty. There is a probability that the use of a “performance chip” will prohibit the engine from starting. In this instance, the vehicle will need to be serviced by a authorized dealer in order to return the vehicle to it’s factory settings. THINGS TO KNOW BEFORE STARTING YOUR VEHICLE CONTENTS 䡵 Steering Wheel Lock — If Equipped . . . . . . . . . . 6 . . . . . . . 6 ▫ To Manually Lock The Steering Wheel ▫ To Release The Steering Wheel Lock . . . . . . . . . 6 䡵 Engine Break-In Recommendations . . . . . . . . . . . 6 6 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE STEERING WHEEL LOCK — IF EQUIPPED Your vehicle may be equipped with a passive steering wheel lock. This lock prevents steering the vehicle with- out the key fob. If the steering wheel is moved approxi- mately a half turn in either direction and the key fob is not in the ignition switch, the steering wheel will lock. To Manually Lock the Steering Wheel With the engine running, turn the steering wheel upside down, turn off the engine and remove the key fob. Turn the steering wheel slightly in either direction until the lock engages. To Release the Steering Wheel Lock Insert the key fob into the ignition switch and start the engine. If the key fob is difficult to turn, move the wheel slightly to the right or left to disengage the lock. If you turned the wheel to the right to engage NOTE: the lock, you must turn the wheel slightly to the right to disengage it. If you turned the wheel to the left to engage the lock, turn the wheel slightly to the left to disengage it. ENGINE BREAK-IN RECOMMENDATIONS The Cummins威 turbocharged diesel engine does not require a break-in period due to its construction. Normal operation is allowed, providing the following recommen- dations are followed: • Warm up the engine before placing it under load. • Do not operate the engine at idle for prolonged • Use the appropriate transmission gear to prevent periods. engine lugging. tors. • Observe vehicle oil pressure and temperature indica- • Check the coolant and oil levels frequently. • Vary throttle position at highway speeds when carry- ing or towing significant weight. NOTE: Light duty operation such as light trailer towing or no load operation will extend the time before the engine is at full efficiency. Reduced fuel economy and power may be seen at this time. THINGS TO KNOW BEFORE STARTING YOUR VEHICLE 7 For additional vehicle break-in requirements, refer to “Trailer Towing” in “Starting and Operating” of the Owners Manual. Because of the construction of the Cummins威 turbo- charged diesel engine, engine run-in is enhanced by loaded operating conditions which allow the engine parts to achieve final finish and fit during the first 6,000 miles (10 000 km). UNDERSTANDING YOUR INSTRUMENT PANEL CONTENTS 䡵 Instrument Cluster . . . . . . . . . . . . . . . . . . . . . 10 䡵 Instrument Cluster Description . . . . . . . . . . . . . 11 䡵 Electronic Vehicle Information Center (EVIC) . . . 21 ▫ Electronic Vehicle Information Center (EVIC) Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 10 UNDERSTANDING YOUR INSTRUMENT PANEL INSTRUMENT CLUSTER INSTRUMENT CLUSTER DESCRIPTION 1. Tachometer The tachometer indicates engine speed in revolutions per minute. CAUTION! Do not operate the engine with the tachometer pointer at high RPM for extended periods. Engine damage may occur. 2. Turn Signal Indicator Light The arrow will flash with the exterior turn signal when the turn signal lever is operated. NOTE: • A continuous chime will sound if the vehicle is driven more than 1 mile (1.6 km) with either turn signal on. UNDERSTANDING YOUR INSTRUMENT PANEL 11 • Check for an inoperative outside light bulb if either indicator flashes at a rapid rate. 3. Fuel Gauge Shows level of fuel in tank when ignition switch is in the ON position. 4. Temperature Gauge The temperature gauge shows engine coolant tempera- ture. Any reading within the normal range indicates that the engine cooling system is operating satisfactorily. The gauge pointer will likely indicate a higher tempera- ture when driving in hot weather, up mountain grades, or when towing a trailer. It should not be allowed to exceed the upper limits of the normal operating range. 12 UNDERSTANDING YOUR INSTRUMENT PANEL WARNING! A hot engine cooling system is dangerous. You or others could be badly burned by steam or boiling coolant. You may want to call an authorized dealer- ship for service if your vehicle overheats. 5. Speedometer The speedometer shows the vehicle speed in miles per hour and/or kilometers per hour (MPH/km/h). 6. O/D OFF Indicator Light – If Equipped This light will illuminate when the TOW HAUL O/D OFF button is pressed twice. The O/D OFF button is located at the end of the gear shift lever. 7. 4LOW Indicator Light – If Equipped This light alerts the driver that the vehicle is in the four-wheel drive LOW mode. The front and rear driveshafts are mechanically locked to- gether forcing the front and rear wheels to rotate at the same speed. Low range provides a greater gear reduction ratio to provide increased torque at the wheels. For vehicles equipped with a premium cluster this indi- cator will display in the Electronic Vehicle Information Center (EVIC). Refer to ”Electronic Vehicle Information Center (EVIC)” in “Understanding Your Instrument Panel” for further information. 8. 4WD Indicator Light – If Equipped This light indicates the vehicle is in four-wheel drive and 4LOCK. 4WD allows all four wheels to receive torque from the engine simulta- neously. 9. 4WD Auto Indicator Light – If Equipped The 4WD AUTO indicator light will be illumi- nated whenever the four-wheel drive mode is automatically engaged. 10. TOW/HAUL Indicator Light – If Equipped The TOW HAUL button is located on the center stack switch bank. This light will illumi- nate when TOW HAUL mode is selected 11. Exhaust Brake Indicator Light This light will illuminate when the exhaust brake has been turned on. 12. Oil Pressure Gauge The pointer should always indicate some oil pressure when the engine is running. A continuous high or low reading under normal driving conditions may indicate a lubrication system malfunction. service Immediate should be obtained from an authorized dealer. UNDERSTANDING YOUR INSTRUMENT PANEL 13 13. Odometer/Trip Odometer Button Press this button to toggle between the odometer and the trip odometer display. Holding the button in resets the trip odometer reading when in trip mode. 14. Odometer/Electronic Vehicle Information Center (EVIC) Display Odometer The odometer shows the total distance the vehicle has been driven. U.S. federal regulations require that upon transfer of vehicle ownership, the seller certify to the purchaser the correct mileage that the vehicle has been driven. Therefore, if the odometer reading is changed during repair or replacement, be sure to keep a record of the reading before and after the service so that the correct mileage can be determined. The two trip odometers show individual trip mileage. To switch from odometer to trip odometers, press and release the TRIP ODOMETER button. 14 UNDERSTANDING YOUR INSTRUMENT PANEL To reset a trip odometer, display the desired trip odom- eter to be reset then push and hold the button for approximately two seconds until the display resets. When the appropriate conditions exist, the following messages will display in the Electronic Vehicle Informa- tion Center (EVIC). Refer to “Electronic Vehicle Informa- tion Center (EVIC)” in “Understanding Your Instrument Panel” for further information. Water in Fuel. . . . . . . . . . . . . . . . . . . . . . (Icon Only) Wait to Start . . . . . . . . . . . . . . . . . . . . . . (Icon Only) NOTE: There is also an engine hour function. This indicates the total number of hours the engine has been running. To display the engine hours, perform the fol- lowing: Turn the ignition switch to the RUN position, but do not start the engine. With the odometer value dis- played, hold the TRIP button down for a period of six seconds. The odometer will change to trip value first, then it will display the engine hour value. The engine hours will be displayed for a period of 30 seconds until the ignition switch is turned OFF or the engine is started. 15. Shift Lever Indicator This display indicator shows the transmission shift lever selection. 16. High Beam Indicator Light This indicator shows that headlights are on high beam. Push the multifunction lever forward to switch the headlights to high beam, and pull toward yourself (normal position) to return to low beam. 17. Voltmeter When the engine is running, the gauge indicates the electrical system voltage. The pointer should stay within the normal range if the battery is charged. If the pointer moves to either extreme left or right and remains there during normal driving, the electrical system should be serviced. NOTE: The voltmeter may show a gauge fluctuation at various engine temperatures. This cycling operation is caused by the post-heat cycle of the intake manifold heater system. The number of cycles and the length of the cycling operation is controlled by the engine control module. Post-heat operation can run for several minutes, and then the electrical system and voltmeter needle will stabilize. 18. Cargo Light The cargo light will illuminate when the cargo light is activated by pressing the cargo light button on the headlight switch. UNDERSTANDING YOUR INSTRUMENT PANEL 15 19. Brake Warning Light This light monitors various brake functions, including brake fluid level and parking brake application. If the brake light turns on, it may indicate that the parking brake is applied, that the brake fluid level is low, or that there is a problem with the Anti-Lock Brake System reservoir. If the light remains on when the parking brake has been disengaged, and the fluid level is at the full mark on the master cylinder reservoir, it indicates a possible brake hydraulic system malfunction or that a problem with the Brake Booster has been detected by the Anti-Lock Brake System (ABS). In this case, the light will remain on until the condition has been corrected. If the problem is related to the brake booster, the ABS pump will run when applying the brake and a brake pedal pulsation may be felt during each stop. 16 UNDERSTANDING YOUR INSTRUMENT PANEL The dual brake system provides a reserve braking capac- ity in the event of a failure to a portion of the hydraulic system. A leak in either half of the dual brake system is indicated by the “Brake Warning Light,” which will turn on when the brake fluid level in the master cylinder has dropped below a specified level. The light will remain on until the cause is corrected. NOTE: The light may flash momentarily during sharp cornering maneuvers, which change fluid level condi- tions. The vehicle should have service performed, and the brake fluid level checked. If brake failure is indicated, immediate repair is neces- sary. WARNING! Driving a vehicle with the “Brake Warning Light” on is dangerous. Part of the brake system may have failed. It will take longer to stop the vehicle. You could have an accident. Have the vehicle checked immediately. Vehicles equipped with the ABS, are also equipped with Electronic Brake Force Distribution (EBD). In the event of an EBD failure, the “Brake Warning Light” will turn on along with the “ABS Warning Light.” Immediate repair to the ABS system is required. Operation of the “Brake Warning Light” can be checked by turning the ignition switch from the OFF position to the ON position. The light should illuminate for approxi- mately two seconds. The light should then turn off unless the parking brake is applied or a brake fault is detected. If the light does not illuminate, have the light inspected by an authorized dealer. The light also will turn on when the parking brake is applied with the ignition switch in the ON position. NOTE: This light shows only that the parking brake is applied. It does not show the degree of brake application. 20. Tire Pressure Monitoring Telltale Light – If Equipped Each tire, including the spare (if provided), should be checked monthly, when cold and inflated to the inflation pressure recommended by the vehicle manufacturer on the vehicle placard or tire inflation pressure label. (If your vehicle has tires of a different size than the size indicated on the vehicle placard or tire inflation pressure label, you should determine the proper tire inflation pressure for those tires.) UNDERSTANDING YOUR INSTRUMENT PANEL 17 As an added safety feature, your vehicle has been equipped with a Tire Pressure Monitoring System (TPMS) that illuminates a low tire pressure telltale when one or more of your tires is significantly under-inflated. Accordingly, when the low tire pressure telltale illumi- nates, you should stop and check your tires as soon as possible, and inflate them to the proper pressure. Driving on a significantly under-inflated tire causes the tire to overheat and can lead to tire failure. Under-inflation also reduces fuel efficiency and tire tread life, and may affect the vehicle’s handling and stopping ability. Please note that the TPMS is not a substitute for proper tire maintenance, and it is the driver’s responsibility to maintain correct tire pressure, even if under-inflation has not reached the level to trigger illumination of the TPMS low tire pressure telltale. 18 UNDERSTANDING YOUR INSTRUMENT PANEL Your vehicle has also been equipped with a TPMS malfunction indicator to indicate when the system is not operating properly. The TPMS malfunction indicator is combined with the low tire pressure telltale. When the system detects a malfunction, the telltale will flash for approximately one minute and then remain continuously illuminated. This sequence will continue upon subse- quent vehicle start-ups as long as the malfunction exists. When the malfunction indicator is illuminated, the sys- tem may not be able to detect or signal low tire pressure as intended. TPMS malfunctions may occur for a variety of reasons, including the installation of replacement or alternate tires or wheels on the vehicle that prevent the TPMS from functioning properly. Always check the TPMS malfunction telltale after replacing one or more tires or wheels on your vehicle, to ensure that the replacement or alternate tires and wheels allow the TPMS to continue to function properly. CAUTION! The TPMS has been optimized for the original equipment tires and wheels. TPMS pressures and warning have been established for the tire size equipped on your vehicle. Undesirable system opera- tion or sensor damage may result when using re- placement equipment that is not of the same size, type, and/or style. Aftermarket wheels can cause sensor damage. Do not use tire sealant from a can, or balance beads if your vehicle is equipped with a TPMS, as damage to the sensors may result. NOTE: The TPMS telltale is also accompanied by a “Low Tire” message in the Electronic Vehicle Information Center (EVIC) screen indicating “Low Tire” for EVIC enabled clusters. 21. Malfunction Indicator Light (MIL) The Malfunction Indicator Light (MIL) is part of an onboard diagnostic (OBDII) system which monitors the emissions and engine control sys- tem. If the vehicle is ready for emissions testing, the light will come on when the ignition is first turned on and remain on, as a bulb check, until the engine is started. If the vehicle is not ready for emissions testing the light will come on when the ignition is first turned on and remain on for 15 seconds, then blink for 5 seconds, and remain on until the vehicle is started. If the bulb does not come on during starting, have the condition investigated promptly. If this light comes on and remains on while driving, it suggests a potential engine control problem and the need for system service. UNDERSTANDING YOUR INSTRUMENT PANEL 19 Although your vehicle will usually be drivable and not need towing, see your authorized dealer for service as soon as possible. CAUTION! Prolonged driving with the MIL on could cause damage to the engine control system. It also could affect fuel economy and drivability. 22. Airbag Warning Light This light turns on and remains on for six to eight seconds as a bulb check when the ignition switch is first turned ON. If the light is not on during starting, stays on, or turns on while driving, have the system inspected by an authorized dealer as soon as possible. 20 UNDERSTANDING YOUR INSTRUMENT PANEL 23. Front Fog Light Indicator Light – If Equipped This indicator will illuminate when the front fog lights are on. 24. Anti-Lock Brake (ABS) Warning Light This light monitors the Anti-Lock Brake System (ABS). The light will turn on when the ignition switch is turned to the ON position and may stay on for as long as four seconds. If the “ABS Warning Light” remains on or turns on while driving, it indicates that the anti-lock portion of the brake system is not functioning and that service is required. However, the conventional brake system will continue to operate normally if the “Brake Warning Light” is not on. If the “ABS Warning Light” is on, the brake system should be serviced as soon as possible to restore the benefits of anti-lock brakes. If the “ABS Warning Light” does not turn on when the ignition switch is turned to the ON position, have the light inspected by an authorized dealer. 25. Seat Belt Reminder Light When the ignition switch is first turned ON, this light will turn on for five to eight seconds as a bulb check. During the bulb check, if the driver’s seat belt is unbuckled, a chime will sound. After the bulb check or when driving, if the driver’s seat belt remains unbuckled, the seat belt reminder light will flash or remain on continuously. Refer to ⬙Occupant Restraints/ Enhanced Seat Belt Use Reminder System (BeltAlert威)⬙ in “Things To Know Before Starting Your Vehicle” in the Owners Manual for further information. 26. Electronic Stability Program (ESP) Indicator Light/Traction Control System (TCS) Indicator Light – If Equipped If the Electronic Stability Program (ESP) / Traction Control System (TCS) Indicator Light begins to flash during acceleration, ease up on the accelerator and apply as little throttle as possible. This indicator light starts to flash as soon as the tires lose traction and the Electronic Stability Program (ESP) becomes active. The ESP/TCS Indicator Light also flashes when TCS is active. Be sure to adapt your speed and driving to the prevailing road conditions. If the ESP/TCS Indicator Light is on solid, the ESP system has been turned off by the driver or a temporary condition exists that will not allow full ESP function. ELECTRONIC VEHICLE INFORMATION CENTER (EVIC) The Electronic Vehicle Information Center (EVIC) fea- tures a driver-interactive display that is located in the instrument cluster. Refer to “Electronic Vehicle Information Center (EVIC)” in “Understanding Your Instrument Panel” of the Own- ers Manual for EVIC operation. UNDERSTANDING YOUR INSTRUMENT PANEL 21 Electronic Vehicle Information Center (EVIC) Electronic Vehicle Information Center (EVIC) Displays When the appropriate conditions exist, the EVIC displays the following messages: • Service Air Filter 22 UNDERSTANDING YOUR INSTRUMENT PANEL • Perform Service • Exhaust Filter XX% Full • Exhaust Filter Full – Power Reduced See Dealer • Service Required – See Dealer Now • Exhaust System – Regeneration Required Now • Exhaust System – Regeneration In Process • Exhaust System – Regeneration Completed Water In Fuel Indicator Light The “Water In Fuel Indicator Light” will illumi- nate when there is water detected in the fuel filter. If this light remains on, DO NOT start the vehicle before you drain the water from the fuel filter to prevent engine damage. Refer to “Maintenance Procedures/ Draining Fuel/Water Separator Filter” in “Maintaining Your Vehicle” for further information. Wait To Start Light The “Wait To Start Light” will illuminate when the ignition is turned to the RUN position and the intake manifold temperature is below 66°F (19°C). Wait until the “Wait To Start Light” turns OFF, then start the vehicle. Refer to “Starting Procedures” in “Starting and Operating” for further information. NOTE: The “Wait To Start Light” may not illuminate if the intake manifold temperature is warm enough. Oil Temp High – Speed May Be Limited If the engine is operated at elevated temperatures for a period of time, this message will be displayed. Engine torque will be reduced until temperatures drop back below the threshold. UNDERSTANDING YOUR INSTRUMENT PANEL 23 1. Turn the ignition switch to the ON position. (Do not start the engine) 2. Fully press the accelerator pedal slowly three times within 10 seconds. 3. Turn the ignition switch to the OFF position. If the indicator message illuminates when you NOTE: start the engine, the oil change indicator system did not reset. If necessary, repeat these steps. Oil Change Required Your vehicle is equipped with an engine oil change indicator system. The Oil Change Required message will flash in the EVIC display for approximately 10 seconds after a single chime has sounded to indicate the next scheduled oil change interval. The engine oil change indicator system is duty-cycle based, which means the engine oil change interval may fluctuate dependent upon your personal driving style. Unless reset, this message will continue to display each time you turn the ignition switch to the ON position. To turn off the message temporarily, press and release the RETURN button. To reset the oil change indicator system (after performing the scheduled maintenance) perform the following steps. STARTING AND OPERATING CONTENTS 䡵 Starting Procedures . . . . . . . . . . . . . . . . . . . . . 28 ▫ Manual Transmission – If Equipped . . . . . . . . 28 ▫ Automatic Transmission – If Equipped . . . . . . 28 ▫ Extreme Cold Weather . . . . . . . . . . . . . . . . . . 28 ▫ Normal Starting Procedure – Engine Manifold Air Temperature Above 66°F (19°C) . . . . . . . . . . . . . . . . . . . . . 29 ▫ Starting Procedure – Engine Manifold Air Temperature 0°F To 66°F (–18°C To 19°C) . . . . 30 ▫ Starting Procedure – Engine Manifold Air Temperature Below 0°F (-18°C) . . . . . . . . . . . . 31 ▫ Starting Fluids . . . . . . . . . . . . . . . . . . . . . . . 33 䡵 Normal Operation – Diesel Engine . . . . . . . . . . 33 ▫ Cold Weather Precautions . . . . . . . . . . . . . . . 34 ▫ Engine Idling . . . . . . . . . . . . . . . . . . . . . . . . 36 ▫ Stopping The Engine . . . . . . . . . . . . . . . . . . . 37 ▫ Engine Speed Control . . . . . . . . . . . . . . . . . . 39 ▫ Operating Precautions . . . . . . . . . . . . . . . . . . 39 26 STARTING AND OPERATING ▫ Cooling System Tips – Automatic Transmission . . . . . . . . . . . . . . . . . . . . . . . . 39 䡵 Engine Block Heater — If Equipped . . . . . . . . . 41 ▫ Block Heater Usage . . . . . . . . . . . . . . . . . . . . 41 䡵 Diesel Exhaust Brake (Engine Braking) — If Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 䡵 Automatic Transmission — If Equipped . . . . . . . 44 ▫ Brake/Transmission Shift Interlock System . . . 45 ▫ Brake/Transmission Interlock Manual Override . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 ▫ Six-Speed Automatic Transmission With Overdrive (68RFE) – If Equipped (Ram Truck Only) . . . . . . . . . . . . . . . . . . . . . 46 ▫ Automatic Transmission With Overdrive (AS68RC) – If Equipped (Chassis Cab Only) . . 52 䡵 Manual Transmission — If Equipped . . . . . . . . . 57 ▫ Shifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 ▫ Downshifting . . . . . . . . . . . . . . . . . . . . . . . . 59 ▫ Reverse Shifting . . . . . . . . . . . . . . . . . . . . . . 61 䡵 Power Take Off Operation — If Equipped (Chassis Cab Only) . . . . . . . . . . . . . . . . . . . . . . 61 ▫ Stationary Mode . . . . . . . . . . . . . . . . . . . . . . 61 ▫ Mobile Mode . . . . . . . . . . . . . . . . . . . . . . . . 62 ▫ Power Take Off – Aftermarket Installation . . . . 63 䡵 Engine Runaway . . . . . . . . . . . . . . . . . . . . . . . 64 䡵 Fuel Requirements . . . . . . . . . . . . . . . . . . . . . . 64 . . . . . . . . . . . . . . . . . . . . 65 ▫ Fuel Specifications 䡵 Adding Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . 66 ▫ Fuel Filler Cap . . . . . . . . . . . . . . . . . . . . . . . 66 STARTING AND OPERATING 27 ▫ Avoid Using Contaminated Fuel . . . . . . . . . . . 67 ▫ Bulk Fuel Storage . . . . . . . . . . . . . . . . . . . . . 67 28 STARTING AND OPERATING STARTING PROCEDURES Before starting your vehicle, adjust your seat, adjust both inside and outside mirrors, and fasten your seat belts. The starter should not be operated for more than 15- second intervals. Waiting a few minutes between such intervals will protect the starter from overheating. WARNING! Do not leave children or animals inside parked vehicles in hot weather. Interior heat build up may cause serious injury or death. Manual Transmission – If Equipped Apply the parking brake, place the shift lever in NEU- TRAL and press the clutch pedal to the floor before starting the vehicle. This vehicle is equipped with a clutch interlocking ignition system. It will not start unless the clutch is fully pressed. Automatic Transmission – If Equipped Start the engine with the shift lever in NEUTRAL or PARK position. Apply the brake before shifting to any driving range. Tip Start Feature Do not press the accelerator. Turn the ignition switch briefly to the START position and release it. The starter motor will continue to run but will automatically disen- gage when the engine is running. Extreme Cold Weather The Cummins威 diesel engine is equipped with several features designed to assist cold weather starting and operation: • The engine block heater is a resistance heater installed in the water jacket of the engine just above and behind the oil filter. It requires a 110–115 Volt AC electrical outlet with a grounded, three-wire extension cord. NOTE: The engine block heater cord is a factory in- stalled option. If your vehicle is not equipped, heater cords are available from your authorized MOPAR威 dealer. • A 12 Volt heater built into the fuel filter housing aids in preventing fuel gelling. It is controlled by a built-in thermostat. • A heated intake air system both improves engine starting and reduces the amount of white smoke generated by a warming engine. Normal Starting Procedure – Engine Manifold Air Temperature Above 66°F (19°C) Observe the instrument panel cluster lights when starting the engine. 1. Always apply the parking brake. STARTING AND OPERATING 29 2. Shift into PARK for an automatic transmission. For vehicles equipped with a manual transmission, fully press and hold the clutch pedal and shift into NEUTRAL. 3. Turn the ignition switch to the ON position and watch the instrument panel cluster lights. CAUTION! If the “Water in Fuel Indicator Light” remains on, DO NOT START the engine before you drain the water from the fuel filter to avoid engine damage. Refer to “Maintenance Procedures/Draining Fuel/Water Sepa- rator Filter” in “Maintaining Your Vehicle” for fur- ther information. 4. Turn the ignition switch to the START position and crank the engine. Do not press the accelerator during starting. 30 STARTING AND OPERATING CAUTION! Do not crank engine for more than 15 seconds at a time or starter motor damage may result. Turn the ignition switch to the OFF position and wait at least two minutes for the starter to cool before repeating start procedure. 5. When the engine starts, release the key fob. 6. Check to see that there is oil pressure. 7. Release the parking brake. Starting Procedure – Engine Manifold Air Temperature 0°F to 66°F (–18°C to 19°C) NOTE: The temperature displayed in the Electronic Vehicle Information Center (EVIC) does not necessarily reflect the engine manifold air temperature. Refer to “Electronic Vehicle Information Center (EVIC)” in “Un- derstanding Your Instrument Panel” for further informa- tion. When engine temperatures fall below 66°F (19°C) the “Wait To Start Light” will remain on indicating the intake manifold heater system is active. Follow the steps in the “Normal Starting” procedure except: 1. The “Wait To Start Light” will remain on for a period of time (length of time depends on engine temperature). CAUTION! If the “Water in Fuel Indicator Light” remains on, DO NOT START engine before you drain the water from the fuel filter to avoid engine damage. Refer to “Maintenance Procedures/Draining Fuel/Water Sepa- rator Filter” in “Maintaining Your Vehicle” for fur- ther information. 2. After the “Wait To Start Light” goes off, turn the ignition switch to the START position. Do not press the accelerator during starting. CAUTION! Do not crank engine for more than 15 seconds at a time or starter motor damage may result. Turn the ignition switch to the OFF position and wait at least two minutes for the starter to cool before repeating start procedure. 3. After engine start-up, check to see that there is oil pressure. 4. Allow the engine to idle about three minutes until the manifold heaters have completed the post-heat cycle. 5. Release the parking brake and drive. STARTING AND OPERATING 31 NOTE: • Engine idle speed will automatically increase to 1,000 RPM at low coolant temperatures to improve engine warm-up. • If the engine stalls, or if the ignition switch is left ON for more than two minutes after the “Wait To Start Light” goes out, reset the grid heaters by turning the ignition switch to the OFF position for at least five seconds and then back ON. Repeat steps 1 through 5 of “Starting Procedure – Engine Manifold Air Tempera- ture Below 66°F (19°C).” Starting Procedure – Engine Manifold Air Temperature Below 0°F (-18°C) In extremely cold weather below 0°F (-18°C) it may be beneficial to cycle the manifold heaters twice before attempting to start the engine. This can be accomplished by turning the ignition OFF for at least five seconds and then back ON after the “Wait To Start Light” has turned 32 STARTING AND OPERATING off, but before the engine is started. However, excessive cycling of the manifold heaters will result in damage to the heater elements or reduced battery voltage. If multiple pre-heat cycles are used before NOTE: starting, additional engine run time may be required to maintain battery state of charge at a satisfactory level. 1. If the engine stalls after the initial start, the ignition must be turned to the OFF position for at least five seconds and then to the ON position to recycle the manifold heaters. NOTE: Excessive white smoke and poor engine perfor- mance will result if manifold heaters are not recycled. 2. Heat generated by the manifold heaters dissipates rapidly in a cold engine. If more than two minutes pass between the time the “Wait To Start Light” turns off and the engine is started, recycle the manifold heaters by turning the ignition switch to the OFF position for at least five seconds and then back ON. 3. If the vehicle is driven and vehicle speed exceeds 19 mph (31 km/h) before the manifold heater post-heat (after start) cycle is complete, the manifold heaters will shut off. 4. If the engine is started before the “Wait To Start Light” turns off, the preheat cycle will turn off. 5. If the engine is cranked for more than 10 seconds, the post-heat cycle will turn off. NOTE: • Engine idle speed will automatically increase to 1, 000 RPM at low coolant temperatures to improve engine warm-up. • When a diesel engine is allowed to run out of fuel or the fuel gels at low temperatures, air is pulled into the fuel system. If your engine has run out of fuel, refer to “Maintenance Procedures/Priming If The Engine Has Run Out Of Fuel” in “Maintaining Your Vehicle” for further information. Starting Fluids WARNING! Starting fluids or flammable liquids are never to be used in the Cummins威 diesel engine (see Warning label). Never pour diesel fuel, flammable liquid, starting fluids (ether) into the air cleaner canister, air intake piping, or turbocharger inlet in an attempt to start the vehicle. This could result in a flash fire and explosion causing serious personal injury and engine damage. The engine is equipped with an automatic electric air preheating system. If the instructions in this manual are followed, the engine should start in all conditions. STARTING AND OPERATING 33 WARNING! Do not leave children or animals inside parked vehicles in hot weather. Interior heat build up may cause serious injury or death. NORMAL OPERATION – DIESEL ENGINE Observe the following when the engine is operating. • All message center lights are off. • Malfunction Indicator Light (MIL) is off. • Engine oil pressure is above 10 psi (69 kPa) at idle. • Voltmeter operation: • The voltmeter may show a gauge fluctuation at various engine temperatures. This cycling operation is caused by the post-heat cycle of the intake mani- fold heater system. The number of cycles and the length of the cycling operation is controlled by the 34 STARTING AND OPERATING engine control module. Post-heat operation can run for several minutes, and then the electrical system and voltmeter needle will stabilize. • The cycling action will cause temporary dimming of the headlamps, interior lamps, and also a noticeable reduction in blower motor speed. Cold Weather Precautions Operation in ambient temperature below 32°F (0°C) may require special considerations. The following charts sug- gest these options: Fuel Operating Range NOTE: Use “Ultra Low Sulfur Diesel Fuels” ONLY. *No. 1 Ultra Low Sulfur Diesel Fuel should only be used where extended arctic conditions (-10°F/-23°C) exist. NOTE: • Use of Climatized Ultra Low Sulfur Diesel Fuel or Number 1 Ultra Low Sulfur Diesel Fuel results in a noticeable decrease in fuel economy. • Climatized Ultra Low Sulfur Diesel Fuel is a blend of Number 2 Ultra Low Sulfur and Number 1 Ultra Low Sulfur Diesel Fuels which reduces the temperature at which wax crystals form in fuel. • The engine requires the use of “Ultra Low Sulfur Diesel Fuel”. Use of incorrect fuel could result in engine and exhaust system damage. Refer to “Fuel Requirements” in “Starting and Operating” for further information. Engine Oil Usage Refer to “Maintenance Procedures” in “Maintaining Your Vehicle” for the correct engine oil viscosity. Winter Front Usage If a winter front or cold weather cover is to be used, a percentage of the total grille opening area must be left uncovered to provide sufficient air flow to the charge air cooler and automatic transmission oil cooler. The per- centage of opening must be increased with the increasing ambient air temperature and/or engine load. If the cooling fan can be heard cycling frequently, increase the size of the opening in the winter front. A suitable cold weather cover is available from your MOPAR威 dealer. STARTING AND OPERATING 35 Battery Blanket Usage A battery loses 60% of its cranking power as the battery temperature decreases to 0°F (-18°C). For the same de- crease in temperature, the engine requires twice as much power to crank at the same RPM. The use of 120 VAC powered battery blankets will greatly increase starting capability at low temperatures. Suitable battery blankets are available from your authorized MOPAR威 dealer. Engine Warm-Up Avoid full throttle operation when the engine is cold. When starting a cold engine, bring the engine up to operating speed slowly to allow the oil pressure to stabilize as the engine warms up. NOTE: High-speed, no-load running of a cold engine can result in excessive white smoke and poor engine performance. No-load engine speeds should be kept under 1,200 RPM during the warm-up period, especially in cold ambient temperature conditions. 36 STARTING AND OPERATING Your vehicle is equipped with a turbo speed limiter, this feature limits the engine speed to 1,200 RPM when engine coolant temperatures are below 70°F (21°C). This feature is designed to protect the turbocharger from damage and will only operate in PARK or NEUTRAL. If temperatures are below 32°F (0°C), operate the engine at moderate speeds for five minutes before full loads are applied. NOTE: • If ambient temperatures are low and the coolant temperature is below 180°F (82°C), the engine idle speed will slowly increase to 1,000 RPM after two minutes of idle, if the following conditions are met: • foot is off brake pedal and throttle pedal • automatic transmission is in PARK • vehicle speed is zero • Applying the throttle will cancel fast idle • If the engine is equipped with an exhaust brake, operating the exhaust brake at idle will greatly im- prove warm up rate and will help keep the engine close to operating temperature during extended idle. Engine Idling Avoid prolonged idling, long periods of idling may be harmful to your engine because combustion chamber temperatures can drop so low that the fuel may not burn completely. Incomplete combustion allows carbon and varnish to form on piston rings, engine valves, and injector nozzles. Also, the unburned fuel can enter the crankcase, diluting the oil and causing rapid wear to the engine. If the engine is allowed to idle, under some conditions the idle speed may increase to 900 RPM then return to normal idle speed. This is normal operation. For EVIC messages related to the vehicle’s NOTE: exhaust system, refer to “Maintenance Procedures/ Intervention Regeneration Strategy – EVIC Message Pro- cess Flow” in “Maintaining Your Vehicle” for further information. Idle-Up Feature – Automatic Transmission Only The driver-controlled high idle speed feature will help increase cylinder temperatures and provide additional cab heat, however, excessive idling may still cause the exhaust aftertreatment system to not properly regenerate. Extended periods of idle time should be avoided. The Idle-Up feature uses the speed control switches to increase engine idle speed and quickly warm the vehi- cle’s interior. 1. With the transmission in PARK, the parking brake applied, and the engine running, press the speed control switch to the ON position, then press the SET switch. STARTING AND OPERATING 37 2. The engine RPM will go up to 1100 RPM. To increase the RPM, press and hold the ACCEL/RESUME switch and the idle speed will increase to approximately 1500 RPM. To decrease the RPM, press and hold the DECEL switch and the idle speed will decrease to approximately 1100 RPM. 3. To cancel the Idle–Up feature, either press the CAN- CEL switch, press the ON/OFF switch, or press the brake pedal. Stopping The Engine Idle the engine a few minutes before routine shutdown. After full load operation, idle the engine three to five minutes before shutting it down. This idle period will allow the lubricating oil and coolant to carry excess heat away from the combustion chamber, bearings, internal components, and turbocharger. This is especially impor- tant for turbocharged, charge air-cooled engines. it transmissions, 38 STARTING AND OPERATING NOTE: • During engine shut down on vehicles equipped with manual is normal for the diesel engine to resonate heavily for a moment during engine shut off. When the engine is connected to a manual transmission, this resonance causes load gear rattle from the transmission. This is commonly referred to as “shut down rattle.” The manufacturer recommends performing engine shut down with the clutch pedal pushed to the floor (clutch disengaged). When engine shut down is performed in this manner the rattle is reduced (not eliminated). to the following chart for proper engine • Refer shutdown. Driving Condition Stop and Go Stop and Go Highway Speeds Load Turbo- charger Temperature Empty Cool Medium Medium Warm City Traffic Maximum GCWR Highway Speeds Uphill Grade Maximum GCWR Maximum GCWR Hot Idle Time (min.) Be- fore Engine Shutdown Less than One One Two Three Four Five Engine Speed Control CAUTION! Prevent overspeeding the engine going downhill. When descending steep grades, use a combination of gears and service brakes to control vehicle/engine speed. Overspeed can cause severe engine damage. Operating Precautions Avoid Overheating The Engine The temperature of the engine coolant (antifreeze) (a mixture of 50% ethylene-glycol and 50% water) must not exceed the normal range of the temperature gauge 240°F (116°C) with a 16 psi (110 kPa) radiator cap. Usually the engine coolant (antifreeze) temperature indi- cated during operation will be to the left of center in the normal range of the gauge. STARTING AND OPERATING 39 Avoid Low Coolant Temperature Operation Continual operation at low engine coolant (antifreeze) temperature below the normal range on the gauge 140°F (60°C) can be harmful to the engine. Low engine coolant (antifreeze) temperature can cause incomplete combus- tion which allows carbon and varnish to form on piston rings and injector nozzles. Also, the unburned fuel can enter the crankcase, diluting the lubricating oil and causing rapid wear to the engine. Cooling System Tips – Automatic Transmission To reduce potential for engine and transmission over- heating in high ambient temperature conditions, take the following actions: • City Driving — When stopped, shift the transmission into NEUTRAL and increase engine idle speed. • Highway Driving — Reduce your speed. 40 STARTING AND OPERATING • Up Steep Hills — Select a lower transmission gear, but try and keep the torque converter clutch engaged. • Air Conditioning — Turn it off temporarily. Do Not Operate The Engine With Low Oil Pressure When the engine is at normal operating temperature, the minimum oil pressures required are: Idle 700 to 800 RPM . . . . . . . . . . . . . . . 10 psi (69 kPa) Full speed and load . . . . . . . . . . . . . . 30 psi (207 kPa) CAUTION! If oil pressure falls to less than normal readings, shut the engine off immediately. Failure to do so could result in immediate and severe engine damage. Do Not Operate The Engine With Failed Parts Practically all failures give some warning before the parts fail. Be on the alert for changes in performance, sounds, and visual evidence that the engine requires service. Some important clues are: • engine misfiring or vibrating severely • sudden loss of power • unusual engine noises • fuel, oil or coolant leaks • sudden change, outside the normal operating range, in • excessive smoke • oil pressure drop the engine operating temperature ENGINE BLOCK HEATER — IF EQUIPPED The engine block heater warms engine coolant and permits quicker starts in cold weather. Connect the heater cord to a ground-fault interrupter protected 110–115 Volt AC electrical outlet with a grounded, three-wire exten- sion cord. The engine block heater cord is routed under the hood to the right side and can be located just behind the grille near the headlamp. NOTE: The engine block heater cord is a factory in- stalled option. If your vehicle is not equipped, heater cords are available from your authorized MOPAR威 dealer. The block heater must be plugged in at least one hour to have an adequate warming effect on the coolant. STARTING AND OPERATING 41 WARNING! Remember to disconnect the cord before driving. Damage to the 110–115 Volt electrical cord could cause electrocution. NOTE: The block heater will require 110 Volts AC and 6.5 Amps to activate the heater element. Block Heater Usage For ambient temperatures below 0°F (-18°C), engine block heater usage is recommended. For ambient temperatures below –20°F (-29°C), engine block heater usage is required. 42 STARTING AND OPERATING DIESEL EXHAUST BRAKE (ENGINE BRAKING) — IF EQUIPPED The exhaust brake feature will only function when the driver turns the exhaust brake switch to the ON position. Once the switch is in the ON position and the vehicle is moving faster than 5 mph (8 km/h); the exhaust brake will automatically operate when the driver removes pressure from the accelerator pedal. Exhaust braking is most effective when the engine RPM is higher. The automatic transmission has been programmed in TOW/ HAUL mode only to downshift more aggressively when the exhaust brake is enabled to increase brake perfor- mance. CAUTION! Use of aftermarket exhaust brakes is not recom- mended and could lead to engine damage Exhaust Brake Switch WARNING! Do not use the exhaust brake feature when driving in icy or slippery conditions as the increased engine braking can cause the rear wheels to slide and the vehicle to swing around with the possible loss of vehicle control, which may cause an accident possi- bly resulting in personal injury or death. NOTE: For optimum braking power it is recommended to use the exhaust brake while in TOW/HAUL mode. The purpose of the exhaust brake (engine braking) fea- ture is to supply negative (braking) torque to the engine. Typically, the engine braking is used for, but not limited to, vehicle towing applications where vehicle braking can be achieved by the internal engine power, thereby spar- ing the mechanical brakes of the vehicle. STARTING AND OPERATING 43 Benefits of the exhaust brake are: • vehicle driving control • reduced brake fade • longer brake life • faster cab warm-up. The exhaust brake feature can also be used to reduce the engine warm up time. To use the exhaust brake as a warm-up device, the vehicle must be stopped or moving less than 5 mph (8 km/h), the exhaust brake switch must be in the ON position, and the coolant temperature must be below 180°F (82°C) and ambient temperature below 60°F (16°C). 44 STARTING AND OPERATING AUTOMATIC TRANSMISSION — IF EQUIPPED CAUTION! a complete stop. Damage to the transmission may occur if the follow- ing precautions are not observed: • Shift into PARK only after the vehicle has come to • Shift into or out of REVERSE only after the vehicle has come to a complete stop and the engine is at idle speed. • Do not shift from REVERSE, PARK, or NEUTRAL into any forward gear when the engine is above idle speed. • Before shifting into any gear, make sure your foot is firmly on the brake pedal. WARNING! • Unintended movement of a vehicle could injure those in and near the vehicle. As with all vehicles, you should never exit a vehicle while the engine is running. Before exiting a vehicle, you should always shift the transmission into PARK, remove the key fob from the ignition, and apply the parking brake. Once the key fob is removed from the ignition, the shift lever is locked in the PARK position, securing the vehicle against unwanted movement. Furthermore, you should never leave unattended children inside a vehicle. (Continued) STARTING AND OPERATING 45 Brake/Transmission Interlock Manual Override Column Shifter There is an override for the BTSI that allows you to move the shift lever out of the PARK position if an electrical system malfunction occurs (i.e., dead battery). 1. Turn the ignition switch to the ACC or ON position without starting the engine. 2. Tilt the steering wheel to the full up position 3. Firmly set the parking brake. 4. Press and maintain firm pressure on the brake pedal. WARNING! (Continued) • It is dangerous to move the shift lever out of PARK or NEUTRAL if the engine speed is higher than idle speed. If your foot is not firmly on the brake pedal, the vehicle could accelerate quickly forward or in reverse. You could lose control of the vehicle and hit someone or something. Only shift into gear when the engine is idling normally and when your right foot is firmly on the brake pedal. Brake/Transmission Shift Interlock System This vehicle is equipped with a Brake Transmission Shift Interlock System (BTSI) that holds the shift lever in the PARK position when the ignition switch is in the LOCK position. To move the shift lever out of the PARK position, the ignition switch must be turned to any other switch position (ACC, ON, or START) (engine running or not) and the brake pedal must be pressed. 46 STARTING AND OPERATING 5. Using the screwdriver, press and hold the override tab through the access port (ringed circle) on the bottom of the steering column. Interlock Manual Override 6. Move the shift lever into the NEUTRAL position. 7. The vehicle may then be started in NEUTRAL. Six-Speed Automatic Transmission with Overdrive (68RFE) – If Equipped (Ram Truck Only) The shift lever display located in the instrument panel cluster indicates the transmission gear range (the selector is illuminated for night driving). The shift lever is mounted on the right side of the steering column. You must press the brake pedal to pull the shift lever out of PARK position (Brake Interlock System). To drive, move the shift lever from PARK or NEUTRAL to the desired DRIVE position. Pull the shift lever toward you when shifting into REVERSE or PARK, or when shifting out of PARK. Electronic Range Select (ERS) Operation The Electronic Range Select (ERS) shift control allows you to move the switch down (-) or up (+) when the shifter is in the D (Drive) position, allowing the selection of the desired top gear. For example, if the driver shifts the transmission into third gear, the transmission will never shift above third gear, but can shift down into second or first gear, when needed. STARTING AND OPERATING 47 will be maintained as the top gear. To disable ERS, simply press and hold the switch up (+) until “D” is displayed in the instrument cluster odometer. WARNING! Do not downshift for additional engine braking on a slippery surface. The drive wheels could lose their grip and the vehicle could skid. 1-4 1-2 1-3 Screen Display Actual Gear(s) Allowed NOTE: To select the proper gear position for maximum deceleration (engine braking), simply press and hold the switch down (-). The transmission will shift to the range from which the vehicle can best be slowed down. 1-6 1-5 Column Shift Lever Switching from ERS to D-Mode can be done at any vehicle speed. To switch from “Drive” mode to “ERS” mode, press the switch down (-) once. The current gear 48 STARTING AND OPERATING Gear Ranges DO NOT race the engine when shifting from PARK or NEUTRAL position into another gear range. PARK This range supplements the parking brake by locking the transmission. The engine can be started in this range. Never use PARK while the vehicle is in motion. Apply the parking brake when leaving the vehicle in this range. Always apply the parking brake first, then place the shift lever into the PARK position. On four-wheel drive ve- hicles be sure that the transfer case is in a drive position. WARNING! • Never use the PARK position as a substitute for the parking brake. Always apply the parking brake fully when parked to guard against vehicle movement and possible injury or damage. (Continued) WARNING! (Continued) • Your vehicle could move and injure you and others if it is not completely in PARK. Check by trying to move the shift lever back and forth without first pulling it toward you after you have set it in PARK. Make sure it is in PARK before leaving the vehicle. • It is dangerous to move the shift lever out of PARK or NEUTRAL if the engine speed is higher than idle speed. If your foot is not firmly on the brake pedal, the vehicle could accelerate quickly forward or in reverse. You could lose control of the vehicle and hit someone or something. Only shift into gear when the engine is idling normally and when your foot is firmly on the brake pedal. REVERSE This range should be used only after the vehicle has come to a complete stop. NEUTRAL Use this range when the vehicle is standing for prolonged periods with the engine running. The engine may be started in this range. Set the parking brake if you must leave the vehicle. DRIVE This range provides underdrive first, second and third gears, direct fourth gear and overdrive fifth and sixth gears. The shift into overdrive fifth and sixth gear occurs only after the transmission has completed the shift into fourth gear. No other movement of the shift mechanism is required to complete the 4–5 or 5–6 gear shifts. Upshifts into both overdrive gears, fifth and sixth, will be delayed when the transmission fluid temperature is below 40° F (4.5° C) or above 240° F (115.5° C). STARTING AND OPERATING 49 NOTE: Use caution when operating a heavily loaded vehicle in second or first gear in high ambient tempera- tures as torque converter slip can impose significant additional heat load on the cooling system. Overdrive Operation The overdrive automatic transmission contains an elec- tronically controlled fifth and sixth (Overdrive). The transmission will automatically shift from DRIVE to Overdrive if the following conditions are present: • the shift lever is in DRIVE; • the engine coolant has reached normal operating tem- • vehicle speed is above approximately 30 mph • the “TOW/HAUL” switch has not been activated; (48 km/h); perature; 50 STARTING AND OPERATING • transmission temperature. has reached normal operating If the vehicle is started in extremely cold tem- NOTE: peratures, the transmission may not shift into Overdrive and will automatically select the most desirable gear for operation at this temperature. Normal operation will resume when the transmission fluid temperature has risen to a suitable level. Refer to the “Note” under “Torque Converter Clutch” later in this section. If the transmission temperature gets extremely hot, the transmission will automatically select the most desirable gear for operation at this temperature. If the transmission temperature becomes hot enough the “Transmission Temperature Warning Light” may illuminate and the transmission may downshift out of Overdrive until the transmission cools down. After cool down, the transmis- sion will resume normal operation. The transmission will downshift from Overdrive to DRIVE if the accelerator pedal is fully pressed at vehicle speeds above approximately 35 mph (56 km/h). When To Use TOW/HAUL When driving in hilly areas, towing a trailer, carrying a heavy load, etc., and frequent transmission shifting oc- curs, press the “TOW/HAUL” switch once to select TOW/HAUL. In TOW/HAUL mode, fourth to fifth gear upshifts are delayed. Shifts into fifth and sixth gear are still allowed under steady cruise conditions. Closed throttle downshifts (for improved engine braking) may occur during steady braking maneuvers. Pressing the switch a second time restores normal operation. Normal operation is always the default at engine start-up. STARTING AND OPERATING 51 Torque Converter Clutch A feature designed to improve fuel economy has been included in the automatic transmission on your vehicle. A clutch within the torque converter engages automati- cally at calibrated speeds. This may result in a slightly different feeling or response during normal operation in the upper gears. When the vehicle speed drops or during acceleration when the transmission downshifts to second gear, the clutch automatically disengages. NOTE: • The torque converter clutch will not engage until the transmission fluid and engine coolant are warm [usu- ally after 1-3 miles (1.6 - 4.8 km) of driving]. Because the engine speed is higher when the torque converter clutch is not engaged, it may seem as if the transmis- sion is not shifting into Overdrive when cold. This is normal. Pressing the “TOW/HAUL” button, when the TOW/HAUL Switch The “TOW/HAUL Indicator Light” will illuminate in the instrument cluster to indicate when the switch has been activated. If the TOW/HAUL modes are desired, the button must be pressed each time the engine is started. 52 STARTING AND OPERATING transmission is sufficiently warm, will demonstrate that the transmission is able to shift into and out of Overdrive. • If the vehicle has not been driven in several days, the first few seconds of operation after shifting the trans- mission into gear may seem sluggish. This is due to the fluid partially draining from the torque converter into the transmission. This condition is normal and will not cause damage to the transmission. The torque con- verter will refill within five seconds of shifting from PARK into any other gear position. Automatic Transmission with Overdrive (AS68RC) – If Equipped (Chassis Cab Only) The shift lever display located in the instrument panel cluster, indicates the transmission gear range (the selector is illuminated for night driving). The shift lever is mounted on the right side of the steering column. You must press the brake pedal to pull the shift lever out of PARK position (Brake Interlock System). To drive, move the shift lever from PARK or NEUTRAL to the desired drive position. Pull the shift lever toward you when shifting into REVERSE, SECOND, FIRST or PARK, or when shifting out of PARK. Gear Ranges DO NOT race the engine when shifting from PARK or NEUTRAL position into another gear range. PARK This range supplements the parking brake by locking the transmission. The engine can be started in this range. Never use PARK while the vehicle is in motion. Apply the parking brake when leaving the vehicle in this range. Always apply parking brake first, then place the shift lever in PARK position. On four-wheel drive vehicles be sure that the transfer case is in a drive position. WARNING! • Never use the PARK position as a substitute for the parking brake. Always apply the parking brake fully when parked to guard against vehicle movement and possible injury or damage. • Your vehicle could move and injure you and others if it is not completely in PARK. Check by trying to move the shift lever back and forth without first pulling it toward you after you have set it in PARK. Make sure it is in PARK before leaving the vehicle. (Continued) STARTING AND OPERATING 53 WARNING! (Continued) • It is dangerous to move the shift lever out of PARK or NEUTRAL if the engine speed is higher than idle speed. If your foot is not firmly on the brake pedal, the vehicle could accelerate quickly forward or in reverse. You could lose control of the vehicle and hit someone or something. Only shift into gear when the engine is idling normally and when your right foot is firmly on the brake pedal. REVERSE This range should be used only after the vehicle has come to a complete stop. NEUTRAL Use this range when the vehicle is standing for prolonged periods with the engine running. The engine may be started in this range. Set the parking brake if you must leave the vehicle. 54 STARTING AND OPERATING DRIVE This range provides all forward gears, including fourth gear direct and fifth or sixth (if equipped) gear overdrive (refer to “Overdrive Operation” in this section). Use this range for most city and highway driving. THIRD This range should be used for driving in slight heavy city traffic or on mountain roads where more precise speed control is desirable. Use it when climbing long grades, and for engine braking when descending moderately steep grades. To prevent excessive engine speed do not exceed 40 mph (64 km/h) in this range. SECOND This range should be used for driving in more severe conditions and lower speeds than THIRD. To prevent excessive engine speed do not exceed 25 mph (40 km/h) in this range. FIRST This range should be used for driving up very steep hills and for engine braking at low speeds 12 mph (19 km/h) or less when going downhill. To prevent excessive engine speed, do not exceed 12 mph (19 km/h) in this range. NOTE: Use caution when operating a heavily loaded vehicle in SECOND or FIRST gear selections in high ambients as torque converter slip can impose significant additional heat load on the cooling system. Overdrive Operation The Overdrive automatic transmission contains an elec- tronically controlled fifth and sixth (if equipped) speed (Overdrive). The transmission will automatically shift from DRIVE to Overdrive if the following conditions are present: • the shift lever is in DRIVE; perature; • the engine coolant has reached normal operating tem- • vehicle speed is above approximately 38 mph (61 km/h) for fifth gear and 50 mph (80 km/h) for sixth gear; • the “TOW HAUL O/D OFF” switch has not been • transmission temperature. activated; operating reached normal has If the vehicle is started in extremely cold tem- NOTE: peratures, the transmission shift schedule initially re- stricts transmission operation in forward gear ranges to third gear until the transmission fluid temperature rises to a suitable level. During this condition, the ability of the vehicle to accelerate under heavily loaded conditions may be reduced. Refer to the “Note” under “Torque Converter Clutch” in this section. STARTING AND OPERATING 55 If the transmission temperature gets extremely hot, the transmission will automatically select the most desirable gear for operation at this temperature. If the transmission temperature becomes hot enough, the “Transmission Temperature Warning Light” may illuminate and the transmission may downshift out of Overdrive until the transmission cools down. After cool down, the transmis- sion will resume normal operation. The transmission will downshift from Overdrive to Drive if the accelerator pedal is fully pressed at vehicle speeds above approximately 35 to 40 mph (57 to 65 km/h) for sixth to fifth and 22 to 25 mph (36 to 40 km/h) for fifth to fourth. When To Use “TOW HAUL” and “O/D OFF” Modes When driving in hilly areas, towing a trailer, carrying a heavy load, etc., and frequent transmission shifting oc- curs, press the “TOW HAUL O/D OFF” switch once to 56 STARTING AND OPERATING select TOW HAUL. This will improve performance and reduce the potential for transmission overheating or failure due to excessive shifting. When operating in “TOW HAUL” mode, sixth gear (if equipped) is disabled and 2-3 and 3-4 and 4–5 shift patterns are modified. Shifts into Overdrive (fifth gear) are allowed during steady cruise (for improved fuel economy). Pressing the “TOW HAUL O/D OFF” switch a second time to select O/D OFF will disable fifth and sixth gear completely, which should eliminate any excessive transmission shifting. The “TOW HAUL” or “O/D OFF” Indicator Light will illuminate in the instrument cluster to indicate when the switch has been activated. Pressing the switch a third time restores normal operation. If the “TOW HAUL” or “O/D OFF” modes are desired, the switch must be pressed each time the engine is started. WARNING! Do not use the TOW HAUL feature when driving in icy or slippery conditions. The increased engine braking can cause the rear wheels to slide, and the vehicle to swing around with the possible loss of vehicle control, which may cause an accident possi- bly resulting in personal injury or death. When To Lock Out Overdrive When driving in hilly areas, towing a trailer, carrying a heavy load, etc., and frequent 6–5–6 or 5–4–5 transmis- sion shifting occurs, press the “TOW HAUL” switch. This will improve performance and reduce the potential for transmission overheating or failure due to excessive shifting. Torque Converter Clutch A feature designed to improve fuel economy has been included in the automatic transmission on your vehicle. A clutch within the torque converter engages automati- cally at calibrated speeds. This may result in a slightly different feeling or response during normal operation in high gear. When the vehicle speed drops or during acceleration when the transmission downshifts to first gear, the clutch automatically disengages. NOTE: • The torque converter clutch will not engage until the transmission fluid and engine coolant are warm [usu- ally after 1-3 miles (1.6 - 4.8 km) of driving]. Because the engine speed is higher when the torque converter clutch is not engaged, it may seem as if the transmis- sion is not shifting into Overdrive when cold. This is normal. Pressing the “TOW HAUL” switch when the transmission is sufficiently warm will demonstrate that the transmission is able to shift into and out of Overdrive. STARTING AND OPERATING 57 • If the vehicle has not been driven in several days, the first few seconds of operation after shifting the trans- mission into gear may seem sluggish. This is due to the fluid partially draining from the torque converter into the transmission. This condition is normal and will not cause damage to the transmission. The torque con- verter will refill within five seconds of shifting from PARK into any other gear position. MANUAL TRANSMISSION — IF EQUIPPED WARNING! You or others could be injured if you leave the vehicle unattended without having the parking brake fully applied. The parking brake should al- ways be applied when the driver is not in the vehicle, especially on an incline. 58 STARTING AND OPERATING CAUTION! Shifting Never drive with your foot resting on the clutch pedal, or attempt to hold the vehicle on a hill with the clutch pedal partially engaged, as this will cause abnormal wear on the clutch. NOTE: During cold weather, you may experience in- creased effort in shifting until the transmission fluid warms up. This is normal. Shift Pattern Truck models with manual transmission are equipped with a clutch interlocking ignition system. The clutch pedal must be fully pressed to start the vehicle. Fully press the clutch pedal before shifting gears. As you release the clutch pedal, lightly press the accelerator pedal. This transmission has a “creeper” first gear (L=Low) which should be used to start from a standing position when carrying a payload or towing a trailer. Damage to the clutch can result from starting in second or third gear with a loaded vehicle. An unloaded vehicle may be launched in second gear. Use each gear in numerical order – do not skip a gear. You should use first gear when starting from a standing position if under heavy load or when pulling a trailer. Recommended Vehicle Shift Speeds To utilize your manual transmission efficiently for both fuel economy and performance, it should be upshifted as listed in recommended shift speed chart. Shift at the STARTING AND OPERATING 59 vehicle speeds listed for acceleration. When heavily loaded or pulling a trailer these recommended up-shift speeds may not apply. Maximum Recommended Up-Shift Speeds Gear Selec- tion Maxi- mum Speed L to 2 2 to 3 3 to 4 4 to 5 5 to 6 7 mph 15 mph 25 mph 40 mph 45 mph (11 (24 (40 (64 (72 km/h) km/h) km/h) km/h) km/h) Downshifting Moving from a high gear down to a lower gear is recommended to preserve brakes when driving down steep hills. In addition, downshifting at the right time provides better acceleration when you desire to resume speed. Downshift progressively. Do not skip gears to avoid overspeeding the engine and clutch. 60 STARTING AND OPERATING WARNING! Do not downshift for additional engine braking on a slippery surface. The drive wheels could lose their grip and the vehicle could skid. CAUTION! When descending a hill, be very careful to downshift one gear at a time to prevent overspeeding the engine which can cause valve damage, and/or clutch disc damage even if the clutch pedal is pressed. Maximum Recommended Downshift Speeds CAUTION! Failure to follow the recommended downshifting speeds may cause the engine to overspeed and/or damage the clutch disc even if the clutch pedal is pressed. Maximum Recommended Downshifting Speeds Gear Selec- tion Maxi- mum Speed 6 to 5 5 to 4 4 to 3 3 to 2 2 to L 68 mph (109 km/h) 50 mph 32 mph 19 mph 10 mph (80 (51 (31 (16 km/h) km/h) km/h) km/h) Reverse Shifting To shift into REVERSE (R), bring the vehicle to a com- plete stop. Press the clutch and pause briefly to allow the gear train to stop rotating. Beginning from the NEUTRAL (N) position, move the shift lever in one quick smooth motion straight across and into the REVERSE (R) area (the driver will feel a firm “click” as the shifter passes the “knock-over”). Complete the shift by pulling the shift lever into REVERSE (R). The “knock-over” prevents the driver from accidentally entering the REVERSE (R) shift area and warns the driver that they are about to shift the transmission into RE- VERSE (R). Due to this feature, a slow shift to REVERSE (R) can be perceived as a high shift effort. To shift out of REVERSE bring the vehicle to a complete stop and press the clutch. Shifting out of REVERSE prior to a complete stop may cause high shift effort. STARTING AND OPERATING 61 POWER TAKE OFF OPERATION — IF EQUIPPED (CHASSIS CAB ONLY) This vehicle when equipped with either the automatic six-speed or manual G-56 six-speed transmissions, will allow for an aftermarket upfit with a transmission driven PTO (power take off). The customer will have the ability to operate the PTO in either a “stationary” or “mobile” mode. The vehicles will be factory set to the “stationary” mode. In order to select the “mobile” mode an authorized dealership is required to modify the vehicle’s settings using their proprietary authorized dealer service tool. Stationary Mode To operate the PTO in this mode the vehicle must meet the following conditions: • Be in PARK position (vehicles equipped with auto- • Upfitter provider (on/off) switch has been activated matic transmission) 62 STARTING AND OPERATING manual transmission) • Parking brake applied (vehicles equipped with • Vehicle engine must be running • No vehicle, brake or clutch switch faults present • PTO must be correctly installed using the vehicle provided circuits The customer has the choice to operate the PTO by utilizing the cruise control switches or by utilizing a remote control (provided by the PTO supplier). To oper- ate the feature using the cruise control switches, the customer must first activate the upfitter-provided on/off switch which will turn on the PTO. In order to increase or decrease the engine idle speed, to optimize the PTO function, the “RESUME/ACCEL” and “DECEL” cruise switches can be used respectively. To disengage PTO operation and return to “standard vehicle operation” simply turn the upfitter-provided on/off switch to the OFF position or press the CANCEL cruise switch. To operate the PTO via a remote switch the customer must make sure the above conditions are met. It is vital for proper operation that the PTO and remote have been installed correctly, paying special attention to ensure the vehicle provided wiring has been connected properly. This is the responsibility of the installer of the PTO and switches/remote system. It is the responsibility of the PTO manufacturer to ensure that their electrical (switches and remote) system is compatible with the vehicle’s electrical architecture and software functionality. Mobile Mode To operate the PTO in this mode the vehicle must meet the following conditions: • Authorized dealer-selected “mobile” mode activated via authorized dealer proprietary service tool equipped with automatic transmission) • Upfitter-provided (on/off) switch has been activated • Vehicle must be in PARK or DRIVE position (vehicles • Parking brake must not be applied • No vehicle, brake or clutch switch faults present • Vehicle engine must be running • PTO must be correctly installed using the vehicle provided circuits The customer may choose to use the PTO while the vehicle is moving. To do so, the PTO function must be activated prior to taking the vehicle out of PARK. This is accomplished by activating the upfitter-provided PTO on/off switch. At this point, the customer may place the vehicle in a forward or reverse gear and have PTO operation. To disengage PTO operation and return to STARTING AND OPERATING 63 “standard vehicle operation” simply turn the upfitter- provided on/off switch to the OFF position. NOTE: For application specific information with respect to PTO and pump requirements and additional vehicle information (wiring schematics, preset idle values, en- gine speed limits, and vehicle hardware and software requirements) please refer to the Dodge Body Builders Guide by accessing “www.dodge.com/bodybuilder” and choosing the appropriate links. Power Take Off – Aftermarket Installation If you did not order the PTO (Power Take Off) Prep Package from the factory and want to convert your vehicle, at www.dodge.com/bodybuilder or contact the manufac- turer directly at [email protected] (e-mail) or (866) 205–4102 (toll free). the Body Builders Guide refer to 64 STARTING AND OPERATING ENGINE RUNAWAY WARNING! In case of engine runaway due to flammable fumes from gasoline spills or turbocharger oil leaks being sucked into the engine, do the following to help avoid personal injury and/or vehicle damage: 1. Turn the ignition switch to the OFF position. 2. Using a CO2 or dry chemical type fire extin- guisher, direct the spray from the fire extinguisher into the grille on the passenger side so that the spray enters the engine air intake. The inlet for the engine air intake is located behind the passenger side headlamp and receives air through the grille. FUEL REQUIREMENTS Use good quality diesel fuel from a reputable supplier in your vehicle. Federal law requires that you must fuel this vehicle with Ultra Low Sulfur Highway Diesel fuel (15 ppm Sulfur maximum) and prohibits the use of Low Sulfur Highway Diesel fuel (500 ppm Sulfur maximum) to avoid damage to the emissions control system. For most year-round service, No. 2 diesel fuel meeting ASTM specification D-975 Grade S15 will provide good perfor- mance. If the vehicle is exposed to extreme cold (below 20°F or -7°C), or is required to operate at colder-than- normal conditions for prolonged periods, use climatized No. 2 diesel fuel or dilute the No. 2 diesel fuel with 50% No. 1 diesel fuel. This will provide better protection from fuel gelling or wax-plugging of the fuel filters. WARNING! Do not use alcohol or gasoline as a fuel blending agent. They can be unstable under certain conditions and hazardous or explosive when mixed with diesel fuel. Diesel fuel is seldom completely free of water. To prevent fuel system trouble, drain the accumulated water from the fuel/water separator using the fuel/water separator drain provided. If you buy good quality fuel and follow the cold weather advice above, fuel conditioners should not be required in your vehicle. If available in your area, a high cetane “premium” diesel fuel may offer improved cold-starting and warm-up performance. STARTING AND OPERATING 65 Fuel Specifications The Cummins威 diesel engine has been developed to take advantage of the high energy content and generally lower cost No. 2 Ultra Low Sulfur diesel fuel or No. 2 Ultra Low Sulfur climatized diesel fuels. Experience has shown that it also operates on No. 1 Ultra Low Sulfur diesel fuels or other fuels within specification. NOTE: • A maximum blend of 5% biodiesel meeting ASTM specification D-6751 may be used with your Cum- mins威 diesel engine. • In addition, commercially available fuel additives are not necessary for the proper operation of your Cum- mins威 diesel engine. • No. 1 Ultra Low Sulfur diesel fuel should only be used where extended arctic conditions (-10°F or -23°C) exist. 66 STARTING AND OPERATING ADDING FUEL CAUTION! To avoid fuel spillage and overfilling, do not “top off” the fuel tank after filling. tank is full. NOTE: • When the fuel nozzle “clicks” or shuts off, the fuel • Tighten the fuel filler cap until you hear a “clicking” sound. This is an indication that the fuel filler cap is properly tightened. • Make sure that the fuel filler cap is tightened each time the vehicle is refueled. WARNING! A fire may result if fuel is pumped into a portable container that is on a truck bed. You could be burned. Always place fuel containers on the ground while filling. Fuel Filler Cap If the fuel filler cap is lost or damaged, be sure the replacement cap is for use with this vehicle. CAUTION! Damage to the fuel system or emission control sys- tem could result from using an improper fuel tank filler tube cap. A poorly fitting cap could let impuri- ties into the fuel system. WARNING! • Never have any smoking materials lit in or near the vehicle when the fuel filler cap is removed or the tank filled. • Never add fuel to the vehicle when the engine is running. Avoid Using Contaminated Fuel Fuel that is contaminated by water or dirt can cause severe damage to the engine fuel system. Proper main- tenance of the engine fuel filter and fuel tank is essential. Refer to “Maintenance Procedures” in “Maintaining Your Vehicle” for further information. Bulk Fuel Storage If you store quantities of fuel, good maintenance of the stored fuel is also essential. Fuel contaminated with water will promote the growth of “microbes.” These STARTING AND OPERATING 67 microbes form “slime” that will clog fuel filters and lines. Drain condensation from the supply tank and change the line filter on a regular basis. NOTE: When a diesel engine is allowed to run out of fuel, air is pulled into the fuel system. If the vehicle will not start, refer to “Maintenance Procedures/Priming If The Engine Has Run Out Of Fuel” in “Maintaining Your Vehicle” for further information. WARNING! Do not open the high pressure fuel system with the engine running. Engine operation causes high fuel pressure. High pressure fuel spray can cause serious injury or death. WHAT TO DO IN EMERGENCIES CONTENTS 䡵 Jump Starting . . . . . . . . . . . . . . . . . . . . . . . . . 70 . . . . . . . . . . . . . . 73 ▫ With Portable Starting Unit 70 WHAT TO DO IN EMERGENCIES JUMP STARTING WARNING! • To prevent personal injury or damage to clothing, do not allow battery fluid to contact eyes, skin or fabrics. Do not lean over a battery when connect- ing jumper cables or allow cable clamps to touch each other. Keep open flames or sparks away from battery vent holes. Always wear eye protection when working with batteries. • Do not use a booster battery or any other booster source that has a greater than 12 Volt system, i.e., do not use a 24 Volt power source. NOTE: Replacement batteries should both be of equal size to prevent damage to the vehicle’s charging system. Your vehicle is equipped with two 12 Volt batteries. If it becomes necessary to use a booster battery with jumper cables to start a vehicle’s engine because its batteries are discharged, the following procedure should be used: Set the parking brake and place an automatic transmis- sion in PARK (or NEUTRAL for a manual transmission). Turn off lights, heater and other electrical loads. Observe charge indicator (if equipped) in both batteries. If the indicator (if equipped) is light or yellow on either battery, replace that battery. CAUTION! Use the jump start procedure only when the charge indicator (if equipped) in both batteries is dark in the center. Do not attempt jump starting when either battery charge indicator (if equipped) is bright or yellow. If the charge indicator (if equipped) has a green dot in the center, failure to start is not due to a discharged battery and cranking system should be checked. 1. Attach one jumper cable to the positive terminal of booster battery and the other end of the same cable to the positive terminal of the discharged battery. WARNING! Do not permit vehicles to touch each other as this

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2010 Dodge RAM Diesel Owners Manual