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idle speed. If your foot is not firmly pressing on the brake pedal, the vehicle could accelerate quickly forward or in reverse. You could lose control of the vehicle and hit someone or some- thing. Only shift into gear when the engine is idling normally and your foot is firmly pressed on the brake pedal.
(Continued)
WARNING! (Continued)
• 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, always apply the parking brake, shift the transmission into PARK, and remove the key fob. Once the key fob is removed, 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. • Never leave children alone in a vehicle. Leaving unattended children in a vehicle is dangerous for a number of reasons. A child or others could be seriously or fatally injured. Do not leave the key fob in the vehicle. A child could operate power windows, other controls, or move the vehicle.
CAUTION!
• Before moving the shift lever out of PARK, you must turn the ignition switch from the LOCK/OFF position to the ON/RUN position, and also press the brake pedal. Otherwise, damage to the shift lever could result. • DO NOT race the engine when shifting from PARK or NEUTRAL into another gear range, as this can damage the drivetrain.
The following indicators should be used to ensure that you have engaged the shift lever into the PARK position: • When shifting into PARK, pull the shift lever toward you and move it all the way counterclockwise until it stops. • Release the shift lever and make sure it is fully seated
in the PARK gate.
STARTING AND OPERATING 69
• Look at the shift lever position display and verify that • With brake pedal released, verify that the shift lever
it indicates the PARK position.
will not move out of PARK.
REVERSE This range is for moving the vehicle backward. Shift into REVERSE 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 and shift the transmission into PARK if you must leave the vehicle.
70 STARTING AND OPERATING
WARNING!
Do not coast in NEUTRAL and never turn off the ignition to coast down a hill. These are unsafe practices that limit your response to changing traffic or road conditions. You might lose control of the vehicle and have an accident.
CAUTION!
Towing the vehicle, coasting, or driving for any other reason with the transmission in NEUTRAL can result in severe transmission damage. Refer to “Recre- ational Towing” in “Starting And Operating” and “Towing A Disabled Vehicle” in “What To Do In Emergencies” for further information.
DRIVE This range should be used for most city and highway driving. It provides the smoothest upshifts and down- shifts, and the best fuel economy. The transmission automatically upshifts through underdrive first, second, and third gears, direct fourth gear and overdrive fifth and sixth gears. The DRIVE position provides optimum driv- ing characteristics under all normal operating conditions. When frequent transmission shifting occurs (such as when operating the vehicle under heavy loading condi- tions, in hilly terrain, traveling into strong head winds, or while towing heavy trailers), use the Electronic Range Select (ERS) feature (refer to “Electronic Range Select (ERS)” in this section) to select a lower gear range. Under these conditions, using a lower gear range will improve performance and extend transmission life by reducing excessive shifting and heat buildup.
If the transmission operating temperature exceeds nor- mal operating limits, the powertrain controller will modify the transmission shift schedule and expand the range of torque converter clutch engagement. This is done to prevent transmission damage due to overheat- ing. If the transmission becomes extremely hot, the “Trans- mission Temperature Warning Light” may illuminate and the transmission may downshift out of Overdrive until the transmission cools down. NOTE: Use caution when operating a heavily loaded vehicle at low speeds (such as towing a trailer up a steep grade, or in stop-and-go traffic) during hot weather. In these conditions, torque converter slip can impose a significant additional heat load on the cooling system. Downshifting the transmission to the lowest possible
STARTING AND OPERATING 71
gear (when climbing a grade), or shifting to NEUTRAL (when stopped in heavy traffic) can help to reduce this excess heat generation. During cold temperatures, transmission operation may be modified depending on engine and transmission temperature as well as vehicle speed. This feature im- proves warm up time of the engine and transmission to achieve maximum efficiency. Engagement of the torque converter clutch is inhibited until the transmission fluid is warm (refer to the “Note” under “Torque Converter Clutch” in this section). On cold starts below 41°F (5°C), fifth and sixth gears may be inhibited briefly. During very cold temperatures (-4°F [-20°C] or below), operation may briefly be limited to third gear only. During this condi- tion, the ability of the vehicle to accelerate under heavily loaded conditions may be reduced. Normal operation will resume once the transmission temperature has risen to a suitable level.72 STARTING AND OPERATING Transmission Limp Home Mode Transmission function is monitored electronically for abnormal conditions. If a condition is detected that could result in transmission damage, Transmission Limp Home Mode is activated. In this mode, the transmission remains in third gear regardless of which forward gear is selected. If the vehicle enters Limp Home Mode at highway speeds, it will initially engage fifth gear, until the vehicle slows to a speed where third gear can be engaged. PARK, REVERSE, and NEUTRAL will continue to operate. Limp Home Mode allows the vehicle to be driven to an authorized dealer for service without damaging the transmission. In the event of a momentary problem, the transmission can be reset to regain all forward gears by performing the following steps: 1. Stop the vehicle.
2. Shift the transmission into PARK. 3. Turn the ignition switch to the LOCK/OFF position. 4. Wait approximately 10 seconds. 5. Restart the engine. 6. Shift into the desired gear range. If the problem is no longer detected, the transmission will return to normal operation. NOTE: Even if the transmission can be reset, we recom- mend that you visit your authorized dealer at your earliest possible convenience. Your authorized dealer has diagnostic equipment to determine if the problem could recur. If the transmission cannot be reset, authorized dealer service is required.
Electronic Range Select (ERS) Operation The Electronic Range Select (ERS) shift control allows the driver to limit the highest available gear when the shift lever is in the DRIVE position. For example, if you shift the transmission into 3 (third gear), the transmission will never shift above third gear, but will shift down into second and first gear normally. You can switch between DRIVE and ERS mode at any vehicle speed. When the shift lever is in the DRIVE position, the transmission will operate automatically, shifting between all available gears. Tapping the ERS (-) switch will activate ERS mode, display the current gear in the instrument cluster, and maintain that gear as the top available gear. Once in ERS mode, tapping the ERS (-) or (+) switch will change the top available gear.
STARTING AND OPERATING 73
Column Shift Lever
To exit ERS mode, simply press and hold the ERS (+) switch until “D” is once again displayed in the shift lever position indicator in the instrument cluster.
74 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, causing an accident or personal injury.
1-2
1-6
1-6
1-5
1-4
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 ERS (-) switch down. The transmission will shift to the range from which the vehicle can best be slowed down. Overdrive Operation The automatic transmission includes an electronically controlled Overdrive (fifth and sixth gears). The trans- mission will automatically shift into the Overdrive gear if the following conditions are present:
ture,
perature,
• the shift lever is in the DRIVE position, • the transmission fluid has reached an adequate tem- • the engine coolant has reached an adequate tempera- • vehicle speed is sufficiently high, and • the “TOW/HAUL” switch has not been activated. When To Use TOW/HAUL Mode When driving in hilly areas, towing a trailer, carrying a heavy load, etc., and frequent transmission shifting oc- curs, press the TOW/HAUL switch to select TOW/ HAUL mode. This will improve performance and reduce the potential for transmission overheating or failure due to excessive shifting.
STARTING AND OPERATING 75
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 could cause an accident possi- bly resulting in personal injury or death.
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 some accelerations, the clutch automatically disengages.
TOW/HAUL Switch
The “TOW/HAUL Indicator Light” will illuminate in the instrument cluster to indicate that TOW/HAUL mode has been activated. Pressing the switch a second time restores normal operation. If the TOW/HAUL mode is desired, the switch must be pressed each time the engine is started.
76 STARTING AND OPERATING NOTE: • The torque converter clutch will not engage until the transmission fluid and engine coolant are warm [usu- ally after 1 to 3 miles (1.6 to 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 transmission is not shifting into Overdrive when cold. This is normal. Using the Electronic Range Select (ERS) feature, when the 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 for 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 after starting the engine.
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.
CAUTION!
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.
Shifting
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.
STARTING AND OPERATING 77
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 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. NOTE: When loaded, pulling a trailer or on a grade, the truck should always start in first gear and not skip gears. 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 the78 STARTING AND OPERATING 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
1 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.
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 1
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)
STARTING AND OPERATING 79
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.
80 STARTING AND OPERATING POWER TAKE OFF OPERATION — IF EQUIPPED (CHASSIS CAB ONLY) This vehicle when equipped with either the AS68RC automatic six-speed or G-56 manual six-speed transmis- sions, will allow for an aftermarket upfit with a transmis- sion 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 vehi- cle’s settings using their proprietary authorized dealer service tool. AS68RC Six-Speed Automatic Transmission Only The PTO drive gear (part of the AS68RC) operates at torque converter turbine speed. The turbine speed will be less than engine speed when the torque converter clutch is not engaged and will be same as engine speed when the torque converter clutch is engaged.
Stationary Mode
matic transmission)
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 • Parking brake applied (vehicles equipped with • Brake pedal must not be applied • Vehicle engine must be running • No vehicle, brake or clutch switch faults present • PTO must be correctly installed using the vehicle
manual transmission)
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. The torque converter lockup clutch will automatically engage at engine speeds above 1,200 RPM (engine speed) in PTO stationary mode. Once engaged, the lockup clutch will remain on and not disengage until the engine speed is below 1,000 RPM. Lockup clutch engagement is desir- able for certain types of PTO applications (AS68RC Six-Speed Automatic Transmission Only).
STARTING AND OPERATING 81
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. If you desire a single PTO speed, your vehicle NOTE: must be wired to use a remote PTO switch. For instruc- tions on programming the SET speed, refer to the LEARNING SET SPEED section of the Body Builder’s Guide which can be found at www.ramtrucks.com.82 STARTING AND OPERATING Mobile Mode
via authorized dealer proprietary service tool
To operate the PTO in this mode the vehicle must meet the following conditions: • Authorized dealer-selected “mobile” mode activated • Upfitter-provided (on/off) switch has been activated • Vehicle must be in PARK or DRIVE position (vehicles • Parking brake must not be applied • Brake pedal 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
equipped with automatic transmission)
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 once the vehicle begins to move. To disengage PTO operation and return to “standard vehicle opera- tion” 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 Body Builders Guide by accessing www.ramtrucks.com and choosing the appro- priate 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, refer to the Body Builder’s Guide at ww- w.ramtrucks.com or contact the manufacturer directly at (866) 205–4102 (toll free).
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.
(Continued)
STARTING AND OPERATING 83
WARNING! (Continued)
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 ASTM84 STARTING AND OPERATING 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. 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.
ADDING FUEL
CAUTION!
STARTING AND OPERATING 85
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.
To avoid fuel spillage and overfilling, do not “top off” the fuel tank after filling.
Fuel Filler Cap
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.
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.
86 STARTING AND OPERATING
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 – Diesel Fuel 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
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.
Diesel Exhaust Fluid Storage Diesel Exhaust Fluid (DEF) is considered a very stable product with a long shelf life. If DEF is kept in tempera- tures between 10° to 90°F (-12° to 32°C), it will last a minimum of one year. DEF is subject to freezing at the lowest temperatures. For example, DEF may freeze at temperatures at or below 12° F (-11° C). The system has been designed to operate in this environment. NOTE: When working with DEF, it is important to know that: • Any containers or parts that come into contact with DEF must be DEF compatible (plastic or stainless steel). Copper, brass, aluminum, iron or non-stainless steel should be avoided as they are subject to corrosion by DEF. • If DEF is spilled, it should be wiped up completely
STARTING AND OPERATING 87
Adding Diesel Exhaust Fluid – Chassis Cab Only The DEF gauge (located on the EVIC display) will display the level of DEF remaining in the tank. Refer to “Electronic Vehicle Information Center (EVIC)” in “Un- derstanding Your Instrument Panel” for further informa- tion. • When the DEF gauge reads 75%, add approximately • When the DEF gauge reads 50%, add approximately • When the DEF gauge reads 25%, add approximately2 gallons (7.5 Liters) to fill the DEF tank.
4 gallons (15 Liters) to fill the DEF tank.
6 gallons (23 Liters) to fill the DEF tank.
NOTE: Driving conditions (altitude, vehicle speed, load, etc.) will effect the amount of DEF that is used in your vehicle.
88 STARTING AND OPERATING DEF Fill Procedure NOTE: Refer to “Fluids, Lubricants, and Genuine Parts” in “Maintaining Your Vehicle” for the correct fluid type. 1. Remove cap from DEF tank (located on drivers side of the vehicle).
2. Insert DEF fill adapter/nozzle into DEF tank filler neck.
Filling the DEF Tank
DEF Filler Cap
CAUTION!
• To avoid DEF spillage, and possible damage to the DEF tank from overfilling, do not “top off” the DEF tank after filling. • When DEF is spilled, clean the area immediately with water or use an absorbent material to soak up and spills on the ground.
3. Stop filling the DEF tank immediately when any of the following happen: DEF stops flowing from the fill bottle into the DEF tank, DEF splashes out the filler neck, or a DEF pump nozzle automatically shuts off. 4. Reinstall cap onto DEF tank.
DIESEL EXHAUST FLUID — CHASSIS CAB ONLY Your vehicle is equipped with a Selective Catalytic Re- duction system in order to meet the very stringent diesel
STARTING AND OPERATING 89
emissions standards required by the Environmental Pro- tection Agency. Selective Catalytic Reduction (SCR) is the first and only technology in decades to be as good for the environment as it is good for business and vehicle performance. The purpose of the SCR system is to reduce levels of NOx (oxides of nitrogen emitted from engines) that are harm- ful to our health and the environment to an almost near-zero level. Small quantities of Diesel Exhaust Fluid (DEF) are injected into the exhaust upstream of a catalyst where, when vaporized, convert smog-forming nitrogen oxides (NOx) into harmless nitrogen (N2) and water vapor (H2O), two natural components of the air we breathe. You can operate with the comfort that your vehicle is contributing to a cleaner, healthier world environment for this and generations to come.90 STARTING AND OPERATING System Overview This vehicle is equipped with a Diesel Exhaust Fluid (DEF) injection system and a Selective Catalytic Reduc- tion (SCR) catalyst to meet the emission requirements. The DEF injection system consists of the following com- ponents: • DEF tank • DEF pump • DEF injector • Electronically-heated DEF lines • DEF control module • NOx sensors • Temperature sensors • SCR catalyst
The DEF injection system and SCR catalyst enable the achievement of diesel emissions requirements; while maintaining outstanding fuel economy, drivability, torque and power ratings. Refer to “Electronic Vehicle Information Center (EVIC)” in “Understanding Your Instrument Panel” for system messages and warnings. NOTE: The DEF pump will run for a period of time after engine shutdown to purge the DEF system. This is normal operation.
WHAT TO DO IN EMERGENCIES
CONTENTS
䡵 Jump Starting . . . . . . . . . . . . . . . . . . . . . . . . . 92
▫ With Portable Starting Unit
. . . . . . . . . . . . . . 95
92 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!
WARNING!
WHAT TO DO IN EMERGENCIES 93
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.
Do not permit vehicles to touch each other as this could establish a ground connection and personal injury could result.
94 WHAT TO DO IN EMERGENCIES
Attaching Booster Cables
1 — Discharged Battery 2 — Booster Battery 2. Connect one end of the other jumper cable to negative (-) post of booster battery. Connect the other end of the jumper cable to a good ground on the engine block of the
vehicle with the discharged battery. Make sure a good connection is made, free of dirt and grease.
WARNING!
• Do not connect the cable to the negative post of the discharge battery. The resulting electrical spark could cause the battery to explode. • During cold weather when temperatures are be- low freezing point, electrolyte in a discharged battery may freeze. Do not attempt jump starting because the battery could rupture or explode. The battery temperature must be brought up above freezing point before attempting to jump start.
3. Take care that the clamps from one cable do not inadvertently touch clamps from the other cable. Do not lean over the battery when making connection. The negative connection must provide good electrical con- ductivity and current carrying capacity.
4. After the engine is started or if the engine fails to start, cables must be disconnected in the following order:
a. Disconnect the negative cable at the engine ground. b. Disconnect the negative cable at the negative post on booster battery. c. Disconnect the cable from the positive post of both batteries.
WARNING!
WHAT TO DO IN EMERGENCIES 95
With Portable Starting Unit There are many types of these units available. Follow the manufacturer’s instructions for necessary precautions and operation.
CAUTION!
It is very important that the starting unit operating voltage does not exceed 12 Volts DC or damage to battery, starter motor, alternator, or electrical system may occur.
the battery vent;
Any procedure other than above could result in: • Personal injury caused by electrolyte squirting out • Personal injury or property damage due to battery • Damage to charging system of booster vehicle or
explosion;
of immobilized vehicle.
MAINTAINING YOUR VEHICLE
CONTENTS
䡵 Engine Compartment — 6.7L Diesel . . . . . . . . . 99
䡵 Maintenance Procedures . . . . . . . . . . . . . . . . . 100
▫ Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . 100
▫ Engine Air Cleaner Filter . . . . . . . . . . . . . . . 104
▫ Draining Fuel/Water Separator Filter . . . . . . 106
▫ Fuel Filter Replacement . . . . . . . . . . . . . . . . 108
▫ Priming If The Engine Has Run Out OfFuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
▫ Intervention Regeneration Strategy – EVIC
Message Process Flow . . . . . . . . . . . . . . . . . . 111
▫ Diesel Exhaust Fluid – Chassis Cab Only . . . 114
▫ Maintenance-Free Batteries . . . . . . . . . . . . . 114
▫ Cooling System . . . . . . . . . . . . . . . . . . . . . 115
▫ Charge Air Cooler – Inter-Cooler . . . . . . . . . 121
▫ Brake System . . . . . . . . . . . . . . . . . . . . . . . 121
▫ Clutch Hydraulic System . . . . . . . . . . . . . . . 123
▫ Transfer Case – If Equipped . . . . . . . . . . . . . 123
▫ Manual Transmission – If Equipped . . . . . . . 123
▫ Automatic Transmission – If Equipped . . . . . 12498 MAINTAINING YOUR VEHICLE
▫ Noise Control System Required Maintenance
& Warranty . . . . . . . . . . . . . . . . . . . . . . . . 127
䡵 Fluid Capacities . . . . . . . . . . . . . . . . . . . . . . 132
䡵 Fluids, Lubricants And Genuine Parts . . . . . . . 133▫ Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
▫ Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . 135ENGINE COMPARTMENT — 6.7L DIESEL
MAINTAINING YOUR VEHICLE 99
1 — Battery 2 — Engine Coolant Reservoir 3 — Automatic Transmission Dipstick (If Equipped) 4 — Engine Oil Dipstick 5 — Brake Fluid Reservoir
6 — Washer Fluid Reservoir 7 — Integrated Power Module 8 — Engine Oil Fill 9 — Coolant Pressure Cap 10 — Air Cleaner Filter
100 MAINTAINING YOUR VEHICLE MAINTENANCE PROCEDURES The pages that follow contain the required maintenance services determined by the engineers who designed your vehicle. Besides those maintenance items specified in the fixed maintenance schedule, there are other components which may require servicing or replacement in the future.
CAUTION!
• Failure to properly maintain your vehicle or per- form repairs and service when necessary could result in more costly repairs, damage to other components or negatively impact vehicle perfor- mance. Immediately have potential malfunctions examined by an authorized Chrysler Group LLC dealership or qualified repair center.
(Continued)
CAUTION! (Continued)
• Your vehicle has been built with improved fluids that protect the performance and durability of your vehicle and also allow extended maintenance intervals. Do not use chemical flushes in these components as the chemicals can damage your engine, transmission, power steering or air condi- tioning. Such damage is not covered by the New Vehicle Limited Warranty. If a flush is needed because of component malfunction, use only the specified fluid for the flushing procedure.
Engine Oil
Checking Oil Level To assure proper lubrication of your vehicle’s engine, the engine oil must be maintained at the correct level. Check the oil level at regular intervals. The best time to check the oil level is before starting the engine after it has been
parked overnight. When checking oil after operating the engine, first ensure the engine is at full operating tem- perature, then wait for 30 minutes after engine shutdown to check the oil.
1 — ADD Range 2 — Full Mark 3 — SAFE Range
MAINTAINING YOUR VEHICLE 101
Checking the oil while the vehicle is on level ground will improve the accuracy of the oil level readings. Add oil only when the level on the dipstick is below the “ADD” mark. The total capacity from the low mark to the high mark is 2 qts (1.9L).CAUTION!
Overfilling or underfilling the crankcase will cause oil aeration or loss of oil pressure. This could damage your engine.
Never operate the engine with oil level below the “ADD” mark or above the upper “SAFE” mark. Change Engine Oil Refer to the “Maintenance Schedule” for the proper maintenance intervals.
102 MAINTAINING YOUR VEHICLE Engine Oil Selection For best performance and maximum protection under all types of operating conditions, the manufacturer only recommends engine oils that are API CJ-4 certified and meet the requirements of Chrysler Group LLC. Use MOPAR威 or an equivalent oil meeting Chrysler Material Standard MS-10902. Products meeting Cummins威 CES 20081 may also be used. The identification of these engine oils are typically located on the back of the oil container. American Petroleum Institute (API) Engine Oil Identification Symbol
This symbol means that the oil has been certified by the American Petro- leum Institute (API). The manufac- turer only recommends API Certified engine oils.
Oils with a high ash content may produce damaging deposits on engine valves and/or aftertreatment system damage. A maximum sulfated ash content of 1.00 mass % is recommended for all oil used in the engine. The same oil change interval is to be followed for synthetic oil as for petroleum based oil. Also, synthetic oil must meet the same performance specifications as petro- leum oil.
CAUTION!
Do not use chemical flushes in your engine oil as the chemicals can damage your engine. Such damage is not covered by the New Vehicle Limited Warranty.
Engine Oil Viscosity (SAE Grade) Use SAE 15W-40 MOPAR威 or an equivalent engine oil meeting Chrysler Material Standard MS-10902. Products meeting Cummins CES 20081 may also be used. The identification of these engine oils is typically located on the back of the oil container. In ambient temperatures below 0°F (-18°C), SAE 5W-40
synthetic engine oil that meets Chrysler Materials Stan- dard MS-10902 and the API CJ-4 engine oil category is required.CAUTION!
Failure to use SAE 5W-40 synthetic engine oil in ambient temperatures below 0°F (-18°C) could result in severe engine damage.
MAINTAINING YOUR VEHICLE 103
Engine oil not designated by the Chrysler or Cummins威 Material Standards and API CJ-4 should not be used, as engine and exhaust system durability may be compro- mised. The engine oil filler cap also shows the recom- mended engine oil viscosity for your engine. For infor- mation on engine oil filler cap location, refer to “Engine Compartment” in “Maintaining Your Vehicle” for further information.
104 MAINTAINING YOUR VEHICLE 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 manufacturer strongly recommends against the ad- dition of any additives (other than leak detection dyes or lube odorants) to the engine oil. Engine oil is an engi- neered product and its performance may be impaired by supplemental additives. Engine Oil Filter Refer to “Fluids, Lubricants, and Genuine Parts” in “Maintaining Your Vehicle” for further information. The engine oil filter should be changed at every engine oil change.
Disposing Of Used Engine Oil And Filter Care should be taken in disposing of the used engine fluids from your vehicle. Used fluids, indiscriminately discarded, can present a problem to the environment. Contact an authorized dealer, service station, or govern- mental agency for advice on recycling programs and where used fluids and filters can be safely discarded in your area. Engine Air Cleaner Filter
CAUTION!
All air entering the engine intake must be filtered. The abrasive particles in unfiltered air will cause rapid wear to engine components.
The condition of the air cleaner filter is monitored by the Engine Control Module. The “SERVICE AIR FILTER”
message will display in the Electronic Vehicle Informa- tion Center (EVIC) when service is required. Refer to “Electronic Vehicle Information Center (EVIC)” in “Un- derstanding Your Instrument Panel” for further informa- tion. Do not remove the top of the air filter housing to inspect the filter element on your diesel engine under normal operating conditions. The “SERVICE AIR FILTER” message could be displayed periodically. This is because engine air flow requirements change based on driving conditions. As the filter becomes more restrictive and air flow requirements increase the “SERVICE AIR FILTER” message will be displayed. The message may not be displayed in subsequent drive cycles if the same conditions are not met. The air filter element should be replaced within 250 miles (402 km) from the first time this message is displayed to ensure proper engine operation during all driving conditions.
MAINTAINING YOUR VEHICLE 105
CAUTION!
Driving with a restricted air filter can cause engine damage. Driving in dusty environments for extended periods will lead to rapid air filter plugging. Action should be taken as soon as the “SERVICE AIR FILTER” message is displayed.
If the vehicle experiences a sudden loss of engine power while being driven in heavy snow or rain, or when plowing snow, and/or the “SERVICE AIR FILTER” mes- sage is displayed on the EVIC along with a chime that repeats every 60 seconds, visually inspect the air filter for snow/ice build up or extreme water saturation. If the air filter is not damaged, remove all snow/ice and reinstall air filter. If the air filter is damaged, replace filter element. NOTE: The air filter housing contains a Mass Air Flow sensor. This sensor is critical to proper engine operation and component longevity. Any damage or modification
106 MAINTAINING YOUR VEHICLE to this sensor could result in major engine and/or exhaust aftertreatment damage. This includes the use of non-approved air filters. Use only MOPAR威 approved air filters or equivalent. A visual inspection of the air cleaner filter element is never recommended under normal circumstances. A badly restricted element may appear clean while a soiled element may be quite effective in filtering particles without restricting air flow. Rely on the Engine Control Module to determine when a filter change is necessary.
CAUTION!
Many aftermarket performance air filter elements do not adequately filter the air entering the engine. Use of such filters can severely damage your engine.
Draining Fuel/Water Separator Filter The fuel filter and water separator assembly is located on the driver’s side of the engine. The best access to the water drain valve is from under the hood.
CAUTION!
• Do not drain the fuel/water separator filter when • Diesel fuel will damage blacktop paving surfaces.
the engine is running.
Drain the filter into an appropriate container.
If water is detected in the water separator while the engine is running, or while the ignition switch is in the ON position, the “Water In Fuel Indicator Light” will illuminate and an audible chime will be heard five times. At this point you should stop the engine and drain the water from the separator.
CAUTION!
If the “Water In Fuel Indicator Light” remains on, DO NOT START the engine before you drain water from the fuel filter to avoid engine damage.
If the “Water In Fuel Indicator Light” comes on and a single chime is heard while you are driving, or with the ignition switch in the ON position, there may be a problem with your water separator wiring or sensor. See your authorized dealer for service. Upon proper draining of the water from the fuel filter, the “Water In Fuel Indicator Light” will remain illuminated for approximately 10 seconds. If the water was drained while the engine was running, the “Water In Fuel Indi- cator Light” may remain on for approximately three minutes.
MAINTAINING YOUR VEHICLE 107
NOTE: Care should be taken in disposing of used fluids from your vehicle. Used fluids, indiscriminately dis- carded, can present a problem to the environment. Con- tact an authorized dealer, service station, or government agency for advice on recycling programs and for where used fluids and filters can be properly disposed of in your area. Drain the fuel/water separator filter when the “Water In Fuel Indicator Light” is ON. Within 10 minutes of vehicle shutdown, turn the drain valve (located on the side of the filter) counterclockwise 1/4 turn, turn the ignition switch to the ON position, and allow any accumulated water to drain. Leave the drain valve open until all water and contaminants have been removed. When clean fuel is visible, close the drain valve by turning it clockwise, and turn the ignition switch to OFF.108 MAINTAINING YOUR VEHICLE NOTE: The fuel/water separator drain valve is located on the bottom of the fuel filter housing. If more than a couple ounces/milliliters of fuel have been drained, follow the directions for “Priming If The Engine Has Run Out Of Fuel.” Fuel Filter Replacement
NOTE: Using a fuel filter that does not meet the manufacturer’s filtration and water separating require- ments can severely impact fuel system life and reliability.
1 — Drain Valve
CAUTION!
• Diesel fuel will damage blacktop paving surfaces.
Drain the filter into an appropriate container.
(Continued)
CAUTION! (Continued)
• Do not prefill the fuel filter when installing a new fuel filter. There is a possibility debris could be introduced into the fuel filter during this action. It is best to install the filter dry and allow the in-tank lift pump to prime the fuel system.
1. Ensure engine is turned off. 2. Place drain pan under the fuel filter drain hose. 3. Open the water drain valve 1/4 turn counterclockwise and completely drain fuel and water into the approved container. 4. Close the water drain valve. 5. Remove lid using a socket or strap wrench. Rotate counterclockwise for removal. Remove used o-ring and discard it.
MAINTAINING YOUR VEHICLE 109
6. Remove the used filter cartridge from the housing and dispose of according to your local regulations. 7. Wipe clean the sealing surfaces of the lid and housing. 8. Install new o-ring back into ring groove on the filter housing and lubricate with clean engine oil. 9. Remove new filter cartridge from plastic bag and install into housing. NOTE: Do not remove cartridge from bag until you reach this step in order to keep cartridge clean. 10. Push down on the cartridge to ensure it is properly seated. Do not pre-fill the filter housing with fuel. 11. Install lid onto housing and tighten to 22.5 ft lbs (30.5 N.m). Do not overtighten the lid. 12. Prime the engine using the procedure in “Priming If The Engine Has Run Out Of Fuel.” Then start the engine and confirm there are no leaks.110 MAINTAINING YOUR VEHICLE Priming If The Engine Has Run Out Of Fuel
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.
1. Add a substantial amount of fuel to the tank, approxi- mately 5 to 10 gal (19L to 38L). 2. Turn the ignition switch to the RUN position, wait for four seconds, then turn the ignition switch back to the OFF position. Repeat this step four times. 3. Start the engine using the “Normal Starting” proce- dure. Refer to “Starting Procedures” in “Starting and Operating” for further information.
CAUTION!
Do not engage the starter motor for more than 15 sec- onds at a time. Allow two minutes between the cranking intervals.
NOTE: The engine may run rough until the air is forced from all the fuel lines.
WARNING!
Do not use alcohol or gasoline as a fuel blending agent. They can be unstable under certain conditions and be hazardous or explosive when mixed with diesel fuel.
CAUTION!
Due to lack of lubricants in alcohol or gasoline, the use of these fuels can cause damage to the fuel system.
NOTE: • A maximum blend of 5% biodiesel, meeting ASTM specification D-6751 may be used with your Cum- mins威 diesel engine. Use of biodiesel mixture in excess of 5% can negatively impact the fuel filter’s ability to separate water from the fuel, resulting in high pressure fuel system corrosion or damage. • Ethanol blends are not recommended or approved for • In addition, commercially available fuel additives are not necessary for the proper operation of your Cum- mins威 diesel engine.
use with your Cummins威 diesel engine.
MAINTAINING YOUR VEHICLE 111
Intervention Regeneration Strategy – EVIC Message Process Flow The Cummins威 diesel engine meets all EPA Heavy Duty Diesel Engine Emissions Standards, resulting in the low- est emitting diesel engine ever produced. To achieve these emissions standards, your vehicle is equipped with a state-of-the-art engine and exhaust system. The engine and exhaust after-treatment system work together to achieve the EPA Heavy Duty Diesel Engine Emissions Standards. These systems are seam- lessly integrated into your vehicle and managed by the Cummins威 Powertrain Control Module (PCM). The PCM manages engine combustion to allow the exhaust sys- tem’s catalyst to trap and burn Particulate Matter (PM) pollutants, with no input or interaction on your part. Additionally, your vehicle has the ability to alert you to additional maintenance required on your truck or engine.
112 MAINTAINING YOUR VEHICLE Refer to the following messages that may be displayed on your Electronic Vehicle Information Center (EVIC):
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 exhaust system. Do not park or operate your vehicle in areas where your exhaust system can contact anything that can burn.
Perform Service Your vehicle will require emissions maintenance at a set interval. To help remind you when this maintenance is due, the Electronic Vehicle Information Center (EVIC) will display “Perform Service”. When the “Perform Ser- vice” message is displayed on the EVIC it is necessary to have the emissions maintenance performed. Emissions
maintenance may include replacing the Closed Crank- case Ventilation (CCV) filter element, and cleaning of the EGR Cooler. The procedure for clearing and resetting the ⬙Perform Service⬙ indicator message is located in the appropriate Service Information. Exhaust System – Regeneration Required Now “Exhaust System — Regeneration Required Now” will be displayed on the Electronic Vehicle Information Center (EVIC) if the exhaust particulate filter reaches 80% of its maximum storage capacity. Under conditions of exclu- sive short duration and low speed driving cycles, your Cummins威 diesel engine and exhaust after-treatment system may never reach the conditions required to re- move the trapped PM. If this occurs, the “Exhaust System — Regeneration Required Now” message will be dis- played in the EVIC. If this message is displayed, you will hear one chime to assist in alerting you of this condition.
By simply driving your vehicle at highway speeds for as little as 45 minutes, you can remedy the condition in the particulate filter system and allow your Cummins威 diesel engine and exhaust after-treatment system to remove the trapped PM and restore the system to normal operating condition. Exhaust Filter XX% Full Indicates that the Diesel Particulate Filter (DPF) is ap- proaching full. Exhaust System – Regeneration In Process Indicates that the Diesel Particulate Filter (DPF) is self- cleaning. Maintain your current driving condition until regeneration is completed. Exhaust System – Regeneration Completed Indicates that the Diesel Particulate Filter (DPF) self- cleaning is completed. If this message is displayed, you will hear one chime to assist in alerting you of this condition.
MAINTAINING YOUR VEHICLE 113
Exhaust Service Required - See Dealer Now Regeneration has been disabled due to a system malfunc- tion. At this point the engine PCM will register a fault code, the instrument panel will display a MIL light.
CAUTION!
See your authorized dealer, as damage to the exhaust system could occur soon with continued operation.
Exhaust Filter Full – Power Reduced See Dealer The PCM derates the engine in order to limit the likeli- hood of permanent damage to the after-treatment sys- tem. If this condition is not corrected and a dealer service is not performed, extensive exhaust after-treatment dam- age can occur. In order to correct this condition it will be necessary to have your vehicle serviced by your local authorized dealer.
114 MAINTAINING YOUR VEHICLE
CAUTION!
See your authorized dealer, as damage to the exhaust system could occur soon with continued operation.
Diesel Exhaust Fluid – Chassis Cab Only Diesel Exhaust Fluid (DEF) sometimes known simply by the name of its active component, UREA—is a key component of selective catalytic reduction (SCR) systems, which help diesel vehicles meet stringent emission regu- lations. DEF is a liquid reducing agent that reacts with engine exhaust in the presence of a catalyst to convert smog-forming nitrogen oxides (NOx) into harmless ni- trogen and water vapor. Refer to “Fluids, Lubricants, and Genuine Parts” in “Maintaining Your Vehicle” for further information. You can receive assistance in locating DEF by calling 866-RAM-INFO (866-726-4636).
Maintenance-Free Batteries The top of the maintenance-free batteries are perma- nently sealed. You will never have to add water, nor is periodic maintenance required. NOTE: Replacement batteries should both be of equal capacity to prevent damage to the vehicle’s charging system.
CAUTION!
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 are identified on the battery case. Also, if a “fast charger” is used while the battery is in vehicle, disconnect both vehicle battery cables before connecting the charger to the battery. Do not use a “fast charger” to provide starting voltage.
WARNING!
Cooling System
MAINTAINING YOUR VEHICLE 115
Battery posts, terminals, and related accessories con- tain lead and lead compounds. Always wash hands after handling the battery.
Battery Blanket Usage A battery loses 60% of its cranking power as the battery temperature decreases to 0°F (-18°). For the same de- crease in temperature, the engine requires twice as much power to crank at the same RPM. The use of 120 Volt AC powered battery blankets will greatly increase starting capability at low temperatures. Suitable battery blankets are available from your authorized MOPAR威 dealer.
WARNING!
You or others can be badly burned by hot engine coolant (antifreeze) or steam from your radiator. If you see or hear steam coming from under the hood, do not open the hood until the radiator has had time to cool. Never try to open a cooling system pressure cap when the radiator is hot.
Engine Coolant Checks Check the engine coolant (antifreeze) protection every 12 months (before the onset of freezing weather, where applicable). If the engine coolant (antifreeze) is dirty or rusty in appearance, the system should be drained, flushed and refilled with fresh engine coolant (anti- freeze). Check the front of the A/C condenser for any
116 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 engine coolant (antifreeze) from the radiator drain cock. If the cap is sealing properly, the engine coolant (anti- freeze) will begin to drain from the coolant recovery bottle. DO NOT REMOVE THE COOLANT PRESSURE CAP WHEN THE COOLING SYSTEM IS HOT.
Cooling System – Drain, Flush, And Refill Refer to the “Maintenance Schedule” for the proper maintenance intervals. If the engine coolant (antifreeze) 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 the old engine coolant (antifreeze) solution. Selection Of Coolant Use only the manufacturers recommended engine cool- ant (antifreeze). Refer to “Fluids, Lubricants, and Genu- ine Parts” in “Maintaining Your Vehicle” for further information.
CAUTION!
• Mixing of engine coolant (antifreeze) other than specified HOAT engine coolant (antifreeze), may result in engine damage and may decrease corro- sion protection. If a non-HOAT engine coolant (antifreeze) is introduced into the cooling system in an emergency, it should be replaced with the specified engine coolant (antifreeze) as soon as possible. • Do not use water alone or alcohol-based engine coolant (antifreeze) products. Do not use addi- tional rust inhibitors or antirust products, as they may not be compatible with the radiator engine coolant (antifreeze) and may plug the radiator.
MAINTAINING YOUR VEHICLE 117
CAUTION! (Continued)
• This vehicle has not been designed for use with Propylene Glycol based engine coolant (anti- freeze). Use of Propylene Glycol based engine coolant (antifreeze) is not recommended.
Adding Coolant Your vehicle has been built with an improved engine coolant (antifreeze) that allows extended maintenance intervals. This engine coolant (antifreeze) can be used up to 5 Years or 105,000 miles (168 000 km) before replace- ment. To prevent reducing this extended maintenance period, it is important that you use the same engine coolant (antifreeze) throughout the life of your vehicle. Please review these recommendations for using Hybrid Organic Additive Technology (HOAT) engine coolant (antifreeze).
118 MAINTAINING YOUR VEHICLE When adding engine coolant (antifreeze): • The manufacturer
recommends using MOPAR威 Antifreeze/Coolant 5 Year/100,000 Mile Formula HOAT (Hybrid Organic Additive Technology) or equivalent. • Mix a minimum solution of 50% HOAT engine coolant (antifreeze) and distilled water. Use higher concentra- tions (not to exceed 70%) if temperatures below -34°F (-37°C) are anticipated. • Use only high purity water such as distilled or deion- ized water when mixing the water/engine coolant (antifreeze) solution. 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 engine coolant (antifreeze) types will decrease the life of the engine coolant (antifreeze) and will require more frequent engine coolant (antifreeze) changes. Cooling System Pressure Cap The cap must be fully tightened to prevent loss of engine coolant (antifreeze), and to ensure that engine coolant (antifreeze) 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 engine coolant (antifreeze) 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 en- gine damage may result.
Disposal Of Used Engine Coolant Used ethylene glycol based engine coolant (antifreeze) is a regulated substance requiring proper disposal. Check with your local authorities to determine the disposal
MAINTAINING YOUR VEHICLE 119
rules for your community. To prevent ingestion by ani- mals or children, do not store ethylene glycol based engine coolant (antifreeze) in open containers or allow it to remain in puddles on the ground. If ingested by a child or pet, seek emergency assistance 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 engine coolant (antifreeze) 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 engine coolant (antifreeze) freeze point or replacing en- gine coolant (antifreeze). Advise your service attendant120 MAINTAINING YOUR VEHICLE of this. As long as the engine operating temperature is satisfactory, the coolant bottle need only be checked once a month. When additional engine coolant (antifreeze) 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 engine coolant (antifreeze) 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. • Check the engine coolant (antifreeze) freeze point in the radiator and in the coolant recovery bottle. If engine coolant (antifreeze) needs to be added, the contents of the coolant recovery bottle must also be protected against freezing. • If frequent engine coolant (antifreeze) additions are required, or if the level in the coolant recovery bottle does not drop when the engine cools, the cooling system should be pressure tested for leaks. • Maintain engine coolant (antifreeze) concentration at 50% HOAT engine coolant (antifreeze) (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. • 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 cooling performance, poor gas mileage, and increased emissions. Charge Air Cooler – Inter-Cooler The charge air cooler is positioned between the radiator and the air conditioner condenser. Air enters the engine through the air cleaner and passes through the turbo- charger, where it is pressurized. This pressurized air rapidly reaches high temperature. The air is then directed through a hose to the charge air cooler and through another hose to the intake manifold of the engine. The air entering the engine has been cooled by about 50° to 100°F (10° to 38°C). This cooling process enables more efficient burning of fuel resulting in fewer emissions.
MAINTAINING YOUR VEHICLE 121
To guarantee optimum performance of the system, keep the surfaces of the charge air cooler, condenser and radiator clean and free of debris. Periodically check the hoses leading to and from the charge air cooler for cracks or loose clamps resulting in loss of pressure and reduced engine performance. Brake SystemBrake Master Cylinder – Brake Fluid Level Check The fluid level of the master cylinder should be checked when performing under the hood service, or immedi- ately if the “Brake System Warning Light” indicates system failure. The brake master cylinder has a translucent plastic reservoir. On the outboard side of the reservoir, there is a “MAX” mark and an “MIN” mark. The fluid level must be kept within these two marks. Do not add fluid above the full mark because leakage may occur at the cap.
122 MAINTAINING YOUR VEHICLE 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” in “Maintaining Your Vehicle” for further information.
WARNING!
• Use only manufacturer’s recommended brake fluid. Refer to “Fluids, Lubricants, and Genuine Parts” in “Maintaining Your Vehicle” for further information. Using the wrong type of brake fluid can severely damage your brake system and/or impair its performance. The proper type of brake fluid for your vehicle is also identified on the original factory installed hydraulic master cylin- der reservoir.
(Continued)
WARNING! (Continued)
• To avoid contamination from foreign matter or moisture, use only new brake fluid or fluid that has been in a tightly closed container. Keep the master cylinder reservoir cap secured at all times. Brake fluid in a open container absorbs moisture from the air resulting in a lower boiling point. This may cause it to boil unexpectedly during hard or prolonged braking, resulting in sudden brake failure. This could result in a accident. • Overfilling the brake fluid reservoir can result in spilling brake fluid on hot engine parts, causing the brake fluid to catch fire. Brake fluid can also damage painted and vinyl surfaces, care should be taken to avoid its contact with these surfaces.
(Continued)
WARNING! (Continued)
• Do not allow petroleum based fluid to contami- nate the brake fluid. Brake seal components could be damaged, causing partial or complete brake failure. This could result in an accident.
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. Transfer Case – If Equipped
Drain And Refill Refer to the “Maintenance Schedule” for the proper maintenance intervals. Lubricant Selection Refer to “Fluids, Lubricants, and Genuine Parts” in “Maintaining Your Vehicle” for further information.
MAINTAINING YOUR VEHICLE 123
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. Manual Transmission – If Equipped
Lubricant Selection Refer to “Fluids, Lubricants, and Genuine Parts” in “Maintaining Your Vehicle” for further information. Fluid Level Check The fluid level can be checked by removing the filler plug. If the level of the lubricant is more than 1/2 in (12 mm) below the bottom of the filler hole while the vehicle is on level ground, enough lubricant should be added to bring the level to 1/4 in (6 mm) below the bottom of the filler hole.
124 MAINTAINING YOUR VEHICLE Automatic Transmission – If Equipped
Lubricant Selection Refer to “Fluids, Lubricants, and Genuine Parts” in “Maintaining Your Vehicle” for further information. Fluid Level Check – Ram Truck Only The fluid level should be checked when the engine is fully warmed up and the fluid in the transmission is at normal operating temperature. At normal operating tem- perature, the fluid cannot be held comfortably between the fingertips. Operation of the transmission 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. To properly check the automatic transmission fluid level, 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 shift lever momentarily into each gear posi- tion ending with the shift lever in PARK. 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 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 room temperature, it should be between the “HOT” (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.
MAINTAINING YOUR VEHICLE 125
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. Fluid Level Check – Chassis Cab Only Check the fluid level while the transmission is at normal operating temperature. This occurs after at least 15 miles (25 km) of driving. At normal operating temperature, the fluid cannot be held comfortably between the fingertips. To properly check the transmission fluid, the following procedure must be used. 1. The vehicle must be on level ground.126 MAINTAINING YOUR VEHICLE 2. Operate the engine at idle speed for a minimum of 60 seconds and normal operating temperature. 3. Fully apply the parking brake and press the brake pedal. 4. Place the shift lever momentarily into each gear posi- tion ending with the shift lever in PARK. Make sure the engine is running at idle speed. 5. Remove the dipstick and determine if the fluid is hot or cold. Hot fluid is approximately 160°F to 175°F (70°C to 82°C). This is the normal operating temperature after the vehicle has been driven at least 15 miles (25 km). The fluid cannot be comfortably held between the fingertips. Only use the cold region of the dipstick as a rough reference when doing initial oil level set after transmis- sion rebuild or transmission refill.
6. Wipe the dipstick clean and reinsert it until seated. 7. 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 a solid coating of oil is seen on both sides of the dipstick. If the fluid is low, add MOPAR威 AS68RC Automatic Transmission Fluid or equivalent as required into the dipstick tube. Do not overfill. Never use any ATF other than MOPAR威 AS68RC Automatic Transmission Fluid or equivalent. After adding any quantity of oil through the dipstick tube, wait a minimum of two 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 to 85°F (20°C to 30°C). If the fluid level is correctly established at room temperature, it should be between the HOT (upper) reference holes when the transmission reaches 160°F to 175°F (70°C to 82°C).
CAUTION!
Be aware that if the fluid level 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 a accurate reading.
8. Check for leaks. Release the parking brake.
MAINTAINING YOUR VEHICLE 127
NOTE: To prevent dirt and water from entering the transmission after checking or adding fluid, make sure 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 the seal remains engaged in the dipstick tube. Fluid And Filter Change Refer to the “Maintenance Schedule” for the proper maintenance intervals. 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.128 MAINTAINING YOUR VEHICLE
Required Maintenance For Noise Control Systems The following maintenance services must be performed every six months or 7,500 miles (12 000 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.
In addition,
Exhaust System Inspect the entire exhaust system for leaks and damaged parts. Devices such as hangers, clamps, and U-bolts should be tight and in good condition. Damaged compo- nents, burned or blown out mufflers, burned or rusted out exhaust pipes should be replaced according to the procedures and specifications outlined in the appropriate service manual. Air Cleaner Assembly Inspect air cleaner housing for proper assembly and fit. Make certain that the air cleaner is properly positioned and that the cover is tight. Check all hoses leading to the air cleaner for tightness. The air filter element must also be clean and serviced according to the instructions out- lined in the Maintenance Schedule section of this manual. 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. − Removal of the air cleaner filter element from the air cleaner housing. − Removal of the air ducting. • EXHAUST SYSTEM − Removal or rendering inoperative exhaust system components including the muffler or tailpipe.
MAINTAINING YOUR VEHICLE 129
• 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 manufacturer’s 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, assembly or in any part, component or system of the vehicle as manufactured by the manufacturer, which, at the time it left the manufacturer’s control, caused noise emissions to exceed Federal standards, are covered by this warranty for the life of the vehicle.
7,500
12 000130 MAINTAINING YOUR VEHICLE Maintenance Log and Service Chart (Diesel Engines) 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
60,000
96 00052,500
84 00045,000
72 00037,500
60 00030,000
48 00022,500
36 00015,000
24 000Noise Systems Maintenance Chart and Service Log — Insert Month, Day, Year under column mileage closest to the mileage at which service was performed.
MAINTAINING YOUR VEHICLE 131
MILES KILOMETERS Exhaust system- inspect Air cleaner assembly-inspect ODOMETER READING PERFORMED BY PERFORMED AT
67,500
108 00075,000
120 00082,500
132 00090,000
144 00097,500
156 000105,000
168 000112,500
180 000120,000
192 000132 MAINTAINING YOUR VEHICLE FLUID CAPACITIES
Fuel (Approximate) 2500/3500 Shortbed Models 2500/3500 Longbed Models Standard Rear Tank – Chassis Cab Only Optional Midship Tank – Chassis Cab Only Diesel Exhaust Fluid Tank (Approximate) – Chassis Cab Only Engine Oil with Filter 6.7L Turbo Diesel Engine Cooling System 6.7L Turbo Diesel Engine (MOPAR威 Engine Coolant/ Antifreeze 5 Year/100,000 Mile Formula or equivalent)
U.S.
34 Gallons 35 Gallons 52 Gallons 22 Gallons 8 Gallons
12 Quarts
5.7 Gallons
Metric
129 Liters 132 Liters 197 Liters 83 Liters 30 Liters
11.4 Liters
21.4 Liters
FLUIDS, LUBRICANTS AND GENUINE PARTS
MAINTAINING YOUR VEHICLE 133
Engine Component Engine Coolant
Engine Oil
Engine Oil Filter Engine Fuel Filter
Crankcase Ventilation Filter Fuel Selection
Fluid, Lubricant, or Genuine Part MOPAR威 Antifreeze/Coolant 5 Year/100,000 Mile Formula HOAT (Hy- brid Organic Additive Technology) or equivalent. In ambient temperatures below 0°F (-18°C), 5W-40 synthetic engine oil that meets Chrysler Materials Standard MS-10902 and the API CJ-4 engine oil category is required. In ambient temperatures above 0°F (-18°C), 15W-40 engine oil that meets Chrysler Materials Standard MS-10902 and the API CJ-4 engine oil category is required. MOPAR威 Engine Oil Filter or equivalent. MOPAR威 Fuel Filter or equivalent. Must meet 5 micron rating. Using a fuel filter that does not meet the manufacturers filtration and water separating requirements can severely impact fuel system life and reli- ability. MOPAR威 CCV Filter or equivalent. Use good quality diesel fuel from a reputable supplier in your vehicle.
134 MAINTAINING YOUR VEHICLE
Component
Diesel Exhaust Fluid – Chassis Cab Only
Fluid, Lubricant, or Genuine Part Federal law requires that you must fuel this vehicle with Ultra Low Sul- fur 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 performance. 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. This vehicle is fully compatible with biodiesel blends up to 5% biodiesel meeting ASTM specification D-975. MOPAR威 Diesel Exhaust Fluid (API Certified) (DEF) or equivalent that has been API Certified to the ISO 22241 standard. Use of fluids not API Certified to ISO 22241 may result in system damage. You can receive as- sistance in locating DEF by calling 866-RAM-INFO (866-726-4636).MAINTAINING YOUR VEHICLE 135
Chassis Component Automatic Transmission – If Equipped (Six-Speed 68RFE) – Ram Truck Only Automatic Transmission – If Equipped (Six-Speed AS68RC) – Chassis Cab Only Clutch Linkage Manual Transmission (G-56) – If Equipped
Fluid, Lubricant, or Genuine Part MOPAR威 ATF+4威 Automatic Transmission Fluid or equivalent licensed ATF+4威 product.
MOPAR威 AS68RC Automatic Transmission Fluid or equivalent.
MOPAR威 Multi-Purpose Grease, NLGI Grade 2 E.P. or equivalent. MOPAR威 ATF+4威 Automatic Transmission Fluid or equivalent licensed ATF+4威 product.
MAINTENANCE SCHEDULES
CONTENTS
䡵 Maintenance Schedule . . . . . . . . . . . . . . . . . . 138
▫ Oil Change Indicator System . . . . . . . . . . . . 139▫ Perform Service Indicator . . . . . . . . . . . . . . 140
▫ Required Maintenance Intervals . . . . . . . . . . 140138 MAINTENANCE SCHEDULES MAINTENANCE SCHEDULE
CAUTION!
Failure to perform the required maintenance items may result in damage to the vehicle.
At Each Stop For Fuel • Check the engine oil level at least 30 minutes after a fully warmed engine is shut off. Checking the oil level while the vehicle is on level ground will improve the accuracy of the oil level reading. Add oil only when the level is at or below the ADD or MIN mark.
Once A Month • Inspect the batteries, and clean and tighten the termi-
nals as required.
• Check the fluid levels of the coolant reservoir, brake master cylinder, and transmission and transfer case (if equipped), add as needed.
equipped).
At Each Oil Change • Change the engine oil filter.
