RAM 2010 Truck Diesel Supplement Owner'S Manual Download Page 1

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Diesel Supplement

OWNE R ’ S MANUAL

2 0 1 0

Ram Truck

Summary of Contents for 2010 Truck Diesel Supplement

Page 1: ...Diesel Supplement OWNE R S MANUAL 2 0 1 0 Ram Truck ...

Page 2: ...UCTION 3 2 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE 5 3 UNDERSTANDING YOUR INSTRUMENT PANEL 9 4 STARTING AND OPERATING 25 5 WHAT TO DO IN EMERGENCIES 69 6 MAINTAINING YOUR VEHICLE 75 7 MAINTENANCE SCHEDULES 113 8 INDEX 139 1 2 3 4 5 6 7 8 ...

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Page 4: ...INTRODUCTION CONTENTS 䡵 A Message From Chrysler Group LLC 4 1 ...

Page 5: ...sure 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 d...

Page 6: ...THINGS TO KNOW BEFORE STARTING YOUR VEHICLE CONTENTS 䡵 Steering Wheel Lock If Equipped 6 To Manually Lock The Steering Wheel 6 To Release The Steering Wheel Lock 6 䡵 Engine Break In Recommendations 6 2 ...

Page 7: ...ition 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 NOTE If you turned the wheel to the right to engage 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 T...

Page 8: ...efore the engine is at full efficiency Reduced fuel economy and power may be seen at this time 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...

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Page 10: ...RSTANDING 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 3 ...

Page 11: ...INSTRUMENT CLUSTER 10 UNDERSTANDING YOUR INSTRUMENT PANEL ...

Page 12: ...ith either turn signal on 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 wil...

Page 13: ...s 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 Cen...

Page 14: ...n authorized dealer 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 veh...

Page 15: ...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 indi...

Page 16: ... 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 possi...

Page 17: ...ure 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 W...

Page 18: ...ld determine the proper tire inflation pressure for those tires 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 inf...

Page 19: ... 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 ve...

Page 20: ...ng 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 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 ...

Page 21: ...s 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 l...

Page 22: ... 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 Electronic Vehicle Information Center EVIC Displays When the appropriate condi...

Page 23: ...ter 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 ...

Page 24: ...age 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 1 Turn the ignition switch to the ON position Do not start the engine 2 Fully press the accelerator pedal slowly three times with...

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Page 26: ...dure 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 4 ...

Page 27: ...erride 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...

Page 28: ...䡵 Adding Fuel 66 Fuel Filler Cap 66 Avoid Using Contaminated Fuel 67 Bulk Fuel Storage 67 4 STARTING AND OPERATING 27 ...

Page 29: ...locking 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 auto...

Page 30: ...ts when starting the engine 1 Always apply the parking brake 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 yo...

Page 31: ... 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 tim...

Page 32: ... 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 A...

Page 33: ... 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 ...

Page 34: ...nual are followed the engine should start in all conditions 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 idl...

Page 35: ...ations 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...

Page 36: ... the winter front A suitable cold weather cover is available from your MOPAR威 dealer 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 tempera...

Page 37: ...n 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 tem...

Page 38: ... and the engine running press the speed control switch to the ON position then press the SET switch 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...

Page 39: ...r 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 Refer to the following chart for proper engine shutdown Driving Condition Load Turbo charger Temperature Idle Time min Be fore Engine Shutdown Stop and Go Empty Cool Less than One Stop and Go Medium One Highway S...

Page 40: ...mal range of the gauge 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 crankca...

Page 41: ...l 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 o...

Page 42: ...y 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 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 Am...

Page 43: ...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 t...

Page 44: ...ue 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 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 eng...

Page 45: ...ing 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...

Page 46: ...lds 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 Brake Transmission Interlock Manual Override Column Shifter There is an override for the BTSI that allows you to move the s...

Page 47: ...iving 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 Electron...

Page 48: ...s 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 Screen Display 1 2 3 4 5 D Actual Gear s Allowed 1 1 2 1 3 1 4 1 5 1 6 NOTE To select the proper gear position for maximum deceleration engine braking simply press and hold the...

Page 49: ...gainst 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 i...

Page 50: ...rs 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 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 tronic...

Page 51: ...luminate 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...

Page 52: ...ult 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 s...

Page 53: ... 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 ...

Page 54: ...rous 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 s...

Page 55: ...eds 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 select...

Page 56: ...is 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 res...

Page 57: ...estores 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...

Page 58: ...g the TOW HAUL switch 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 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...

Page 59: ...use 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 Truck models with manual transmission are equipped with a clutch interlocking ignition system The clutch pedal must be fully pressed to start the vehicle Shift Pattern 58 STARTING AND OPERATING ...

Page 60: ...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 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 L to 2 2 to 3 3 to 4 4 to 5 5 to 6 Maxi mum Speed 7 mph...

Page 61: ...ve 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 6 to 5 5 to 4 4 to 3 3 to 2 2 to L Maxi mum Speed 68 mph 109 km h 50 mph ...

Page 62: ...ehicle to a complete stop and press the clutch Shifting out of REVERSE prior to a complete stop may cause high shift effort 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 ...

Page 63: ...d 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 conn...

Page 64: ...have PTO operation To disengage PTO operation and return to 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 D...

Page 65: ...TS 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 Grad...

Page 66: ...ed 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...

Page 67: ...ghtened 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 resul...

Page 68: ... 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 Maint...

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Page 70: ...WHAT TO DO IN EMERGENCIES CONTENTS 䡵 Jump Starting 70 With Portable Starting Unit 73 5 ...

Page 71: ...essary 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 ligh...

Page 72: ...f the same cable to the positive terminal of the discharged battery WARNING Do not permit vehicles to touch each other as this could establish a ground connection and personal injury could result Attaching Booster Cables 1 Discharged Battery 2 Booster Battery 5 WHAT TO DO IN EMERGENCIES 71 ...

Page 73: ... 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 capaci...

Page 74: ...tem of booster vehicle or of immobilized vehicle 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 5 WHAT TO DO IN EMERGEN...

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Page 76: ... Separator Filter 84 Priming If The Engine Has Run Out Of Fuel 88 Intervention Regeneration Strategy EVIC Message Process Flow 89 Maintenance Free Batteries 92 Cooling System 93 Charge Air Cooler Inter Cooler 98 Brake System 99 Clutch Hydraulic System 100 Transfer Case If Equipped 100 Manual Transmission If Equipped 101 Automatic Transmission If Equipped 101 6 ...

Page 77: ... Noise Control System Required Maintenance Warranty 105 䡵 Fluid Capacities 109 䡵 Fluids Lubricants And Genuine Parts 110 Engine 110 Chassis 112 76 MAINTAINING YOUR VEHICLE ...

Page 78: ...ant Reservoir 8 Washer Fluid Reservoir 3 Automatic Transmission Dipstick If Equipped 9 Engine Oil Fill 4 Brake Fluid Reservoir 10 Coolant Pressure Cap 5 Clutch Master Cylinder Manual Transmission Only 11 Air Cleaner Filter 6 Integrated Power Module 6 MAINTAINING YOUR VEHICLE 77 ...

Page 79: ...lified 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 Warra...

Page 80: ...l 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 Oil Change Indicator System in Maintenance Schedu...

Page 81: ...l 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 followe...

Page 82: ...ategory 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 6 MAINTAINING YOUR VEHICLE 81 ...

Page 83: ...e 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 eve...

Page 84: ...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 shoul...

Page 85: ...ved 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 filt...

Page 86: ...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 NOTE Care should be taken in disposing of used fluids from your vehicle Used fluids indiscriminately dis carded can present a problem t...

Page 87: ...unces milliliters of fuel have been drained refer to Maintenance Procedures Priming If The Engine Has Run Out Of Fuel in Maintaining Your Vehicle for further information 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 CAUTION Diesel fuel will damage blacktop pav...

Page 88: ...scard it 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...

Page 89: ...osition 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 4 Repeat the procedure if the engine does not start 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 force...

Page 90: ...eration 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 ...

Page 91: ...s maintenance may include replacing the Closed Crank case Ventilation CCV filter element cleaning of the EGR Cooler and cleaning of the EGR Valve 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 overhead console o...

Page 92: ... cleaning is completed If this message is displayed you will hear one chime to assist in alerting you of this condition 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 wi...

Page 93: ...al 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...

Page 94: ... 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 accumulation of bugs leaves etc If dirty clean by gentl...

Page 95: ...s Lubricants and Genu ine Parts in Maintaining Your Vehicle for the correct fluid type 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 speci fied engine coolant...

Page 96: ...rid 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 cor...

Page 97: ...e pres sure cap while the system is hot or under pressure Continued WARNING Continued 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 r...

Page 98: ...ay 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 va...

Page 99: ...nter 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 e...

Page 100: ...s 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 the correct fluid type WARNING Use only manufacturer s recommended brake fluid Refer to Fluids Lubricants and Genuine Parts in Maintaining Your Vehicl...

Page 101: ...d 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 s...

Page 102: ...bottom of the filler hole Automatic Transmission If Equipped Lubricant Selection Refer to Fluids Lubricants and Genuine Parts in Maintaining Your Vehicle for the correct fluid type Fluid Level Check 68RFE Ram Truck Only If your vehicle is equipped with a dipstick use the following procedure If your vehicle has a capped dip stick tube it is sealed and should not be tampered with Your authorized dea...

Page 103: ...ure 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 NOTE If it is necessary to check the transmission below the operating temperat...

Page 104: ...erating 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 2 Operate the engine at idle speed for a minimum of 60 seconds and normal operating temperature 3 Fully apply the parki...

Page 105: ...lent 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 NOTE If it is necessary to check the transmission below 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 f...

Page 106: ...ight 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 Required Maintenance For Noise Control Systems The following maintenance services must be performed every six months or 7 500 miles 12 000 km whic...

Page 107: ...lement 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 ra...

Page 108: ... 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 ...

Page 109: ...0 52 500 60 000 KILOMETERS 12 000 24 000 36 000 48 000 60 000 72 000 84 000 96 000 Exhaust system inspect Air cleaner assembly inspect ODOMETER READING PERFORMED BY PERFORMED AT MILES 67 500 75 000 82 500 90 000 97 500 105 000 112 500 120 000 KILOMETERS 108 000 120 000 132 000 144 000 156 000 168 000 180 000 192 000 Exhaust system inspect Air cleaner assembly inspect ODOMETER READING PERFORMED BY ...

Page 110: ...e Oil with Filter 6 7L Turbo Diesel Engine 12 Quarts 11 4 Liters Cooling System 6 7L Turbo Diesel Engine MOPAR威 Engine Coolant Antifreeze 5 Year 100 000 Mile Formula or equivalent 5 7 Gallons 21 4 Liters 6 MAINTAINING YOUR VEHICLE 109 ...

Page 111: ...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 Engine Oil Filter MOPAR威 Engine Oil Filter or equivalent Engine Fuel Filter MOPAR威 Fuel Filter or equivalent Must meet 5 micron rating Using a fuel filter that does not meet the manufacturers...

Page 112: ...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 pro longed periods use climatized No 2 diesel fuel or dilute the No 2 diesel fuel with 50 No 1 diesel fuel This will provide bette...

Page 113: ...ivalent licensed ATF 4威 product Automatic Transmission Six Speed AS68RC Chassis Cab Only MOPAR威 AS68RC Automatic Transmission Fluid or equivalent Clutch Linkage MOPAR威 Multi Purpose Grease NLGI Grade 2 E P or equivalent Manual Transmission G 56 MOPAR威 ATF 4威 Automatic Transmission Fluid or equivalent licensed ATF 4威 product 112 MAINTAINING YOUR VEHICLE ...

Page 114: ...MAINTENANCE SCHEDULES CONTENTS 䡵 Maintenance Schedule 114 Oil Change Indicator System 115 Perform Service Indicator 116 Required Maintenance Intervals 116 7 ...

Page 115: ...onth 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 At Each Oil Change Change the engine oil filter Inspect the exhaust system Check the automatic transmission fluid level if equipped Check the manual transmission fluid level if equipped Check t...

Page 116: ... of more frequent regeneration of the exhaust after treat ment system which can decrease the life of the engine oil Failure to change the engine oil per the maintenance schedule can result in internal engine damage For information on resetting the Oil Change Indicator message refer to Oil Change Required under EVIC Displays in the Electronic Vehicle Information Center EVIC section of this manual W...

Page 117: ...ance 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 cleaning of the EGR Cooler and cleaning of the EGR Valve The procedure for clearing and resettin...

Page 118: ...miles 12 000 km or six months since the last oil and filter change change the engine oil and engine oil filter Under no circumstances should oil change intervals exceed 7 500 miles 12 000 km or six months whichever comes first Rotate tires Lubricate front drive shaft fitting 4x4 Lubricate outer tie rod ends Odometer Reading Date Repair Order Dealer Code Signature Authorized Chrysler Dealer 7 MAINT...

Page 119: ...rvals exceed 7 500 miles 12 000 km or six months whichever comes first Rotate tires Replace fuel filter element Lubricate front drive shaft fitting 4x4 Lubricate outer tie rod ends Inspect the front suspension tie rod ends and boot seals for cracks or leaks and all parts for damage wear improper looseness or end play replace if necessary Inspect the front 4x4 and rear axle fluid change if using yo...

Page 120: ...filter change change the engine oil and engine oil filter Under no circumstances should oil change intervals exceed 7 500 miles 12 000 km or six months whichever comes first Rotate tires Inspect drive belt replace if necessary Lubricate front drive shaft fitting 4x4 Lubricate outer tie rod ends Inspect brake linings Inspect and adjust parking brake if necessary Odometer Reading Date Repair Order D...

Page 121: ...r comes first Rotate tires Replace fuel filter element Lubricate front drive shaft fitting 4x4 Lubricate outer tie rod ends Inspect the wheel bearings Inspect the front suspension tie rod ends and boot seals for cracks or leaks and all parts for damage wear improper looseness or end play replace if necessary Inspect the front 4x4 and rear axle fluid change if using your vehicle for police taxi fle...

Page 122: ... miles 12 000 km or six months since the last oil and filter change change the engine oil and engine oil filter Under no circumstances should oil change intervals exceed 7 500 miles 12 000 km or six months whichever comes first Rotate tires Lubricate front drive shaft fitting 4x4 Lubricate outer tie rod ends Odometer Reading Date Repair Order Dealer Code Signature Authorized Chrysler Dealer 7 MAIN...

Page 123: ...ever comes first Rotate tires Inspect drive belt replace as necessary Replace fuel filter element Lubricate front drive shaft fitting 4x4 Lubricate outer tie rod ends Inspect the front suspension tie rod ends and boot seals for cracks or leaks and all parts for damage wear improper looseness or end play replace if necessary Inspect brake linings Inspect and adjust parking brake if necessary Inspec...

Page 124: ... miles 12 000 km or six months since the last oil and filter change change the engine oil and engine oil filter Under no circumstances should oil change intervals exceed 7 500 miles 12 000 km or six months whichever comes first Rotate tires Lubricate front drive shaft fitting 4x4 Lubricate outer tie rod ends Odometer Reading Date Repair Order Dealer Code Signature Authorized Chrysler Dealer 7 MAIN...

Page 125: ...ie rod ends Inspect the wheel bearings Inspect the front suspension tie rod ends and boot seals for cracks or leaks and all parts for damage wear improper looseness or end play replace if necessary Inspect the front 4x4 and rear axle fluid change if using your vehicle for police taxi fleet off road or frequent trailer towing Change automatic transmission fluid and sump filter Chassis Cab Only Chan...

Page 126: ...ange the engine oil and engine oil filter Under no circumstances should oil change intervals exceed 7 500 miles 12 000 km or six months whichever comes first Rotate tires Lubricate front drive shaft fitting 4x4 Lubricate outer tie rod ends Inspect brake linings Inspect and adjust parking brake if necessary Replace Crankcase Ventilation Filter CCV Clean EGR Cooler Ram Truck Only Odometer Reading Da...

Page 127: ... first Rotate tires Flush and replace engine coolant at 60 months if not replaced at 97 500 miles 157 000 km Inspect drive belt replace as necessary Replace fuel filter element Lubricate front drive shaft fitting 4x4 Lubricate outer tie rod ends Inspect the front suspension tie rod ends and boot seals for cracks or leaks and all parts for damage wear improper looseness or end play replace if neces...

Page 128: ... miles 12 000 km or six months since the last oil and filter change change the engine oil and engine oil filter Under no circumstances should oil change intervals exceed 7 500 miles 12 000 km or six months whichever comes first Rotate tires Lubricate front drive shaft fitting 4x4 Lubricate outer tie rod ends Odometer Reading Date Repair Order Dealer Code Signature Authorized Chrysler Dealer 7 MAIN...

Page 129: ... as required Replace fuel filter element Lubricate front drive shaft fitting 4x4 Lubricate outer tie rod ends Inspect the wheel bearings Inspect the front suspension tie rod ends and boot seals for cracks or leaks and all parts for damage wear improper looseness or end play replace if necessary Inspect brake linings Inspect and adjust parking brake if necessary Inspect the front 4x4 and rear axle ...

Page 130: ... change change the engine oil and engine oil filter Under no circumstances should oil change intervals exceed 7 500 miles 12 000 km or six months whichever comes first Rotate tires Lubricate front drive shaft fitting 4x4 Lubricate outer tie rod ends Flush and replace engine coolant if not replaced at 60 months Flush and replace power steering fluid 3500 Ram Truck Only Odometer Reading Date Repair ...

Page 131: ...six months whichever comes first Rotate tires Inspect drive belt replace as required Replace fuel filter element Lubricate front drive shaft fitting 4x4 Lubricate outer tie rod ends Inspect the front suspension tie rod ends and boot seals for cracks or leaks and all parts for damage wear improper looseness or end play replace if necessary Flush and replace power steering fluid Inspect the front 4x...

Page 132: ...nce the last oil and filter change change the engine oil and engine oil filter Under no circumstances should oil change intervals exceed 7 500 miles 12 000 km or six months whichever comes first Rotate tires Lubricate front drive shaft fitting 4x4 Lubricate outer tie rod ends Inspect brake linings Inspect and adjust parking brake if necessary Odometer Reading Date Repair Order Dealer Code Signatur...

Page 133: ... fitting 4x4 Lubricate outer tie rod ends Inspect the wheel bearings Inspect the front suspension tie rod ends and boot seals for cracks or leaks and all parts for damage wear improper looseness or end play replace if necessary Inspect the front 4x4 and rear axle fluid change if using your vehicle for police taxi fleet off road or frequent trailer towing Change automatic transmission fluid and sum...

Page 134: ...0 miles 12 000 km or six months since the last oil and filter change change the engine oil and engine oil filter Under no circumstances should oil change intervals exceed 7 500 miles 12 000 km or six months whichever comes first Rotate tires Lubricate front drive shaft fitting 4x4 Lubricate outer tie rod ends Odometer Reading Date Repair Order Dealer Code Signature Authorized Chrysler Dealer 7 MAI...

Page 135: ...eplace as required Replace fuel filter element Lubricate front drive shaft fitting 4x4 Lubricate outer tie rod ends Inspect the front suspension tie rod ends and boot seals for cracks or leaks and all parts for damage wear improper looseness or end play replace if necessary Inspect brake linings Inspect and adjust parking brake if necessary Inspect the front 4x4 and rear axle fluid change if using...

Page 136: ...0 miles 12 000 km or six months since the last oil and filter change change the engine oil and engine oil filter Under no circumstances should oil change intervals exceed 7 500 miles 12 000 km or six months whichever comes first Rotate tires Lubricate front drive shaft fitting 4x4 Lubricate outer tie rod ends Odometer Reading Date Repair Order Dealer Code Signature Authorized Chrysler Dealer 7 MAI...

Page 137: ...lace as required Adjust valve lash clearance Lubricate front drive shaft fitting 4x4 Lubricate outer tie rod ends Inspect the wheel bearings Inspect the front suspension tie rod ends and boot seals for cracks or leaks and all parts for damage wear improper looseness or end play replace if necessary Flush and replace engine coolant at 120 months if not replaced at 97 500 miles 157 000 km Inspect th...

Page 138: ...he manufacturer highly recommends that all cooling system service maintenance and repairs be performed by your local authorized dealer WARNING You can be badly injured working on or around a motor vehicle Do only service work for which you have the knowledge and the right equipment If you have any doubt about your ability to perform a service job take your vehicle to a competent mechanic Failure t...

Page 139: ......

Page 140: ...INDEX 8 ...

Page 141: ... Axle Fluid 112 Battery 92 Blanket 35 93 Emergency Starting 70 Brake Fluid 112 Brake System 99 Fluid Check 99 Master Cylinder 99 Warning Light 15 Brake Transmission Interlock 45 Capacities Antifreeze Engine Coolant 109 Capacities Fluid 109 Caps Filler Oil Engine 81 Radiator Coolant Pressure 96 Charge Air Cooler 98 Check Engine Light Malfunction Indicator Light 19 Coolant Pressure Cap Radiator Cap ...

Page 142: ...iming 88 Dipsticks 78 Disposal 82 Antifreeze Engine Coolant 96 Engine Oil 82 Draining Fuel Water Separator Filter 84 Electronic Range Select ERS 46 Electronic Vehicle Information Center EVIC 21 Emergency In Case of Jump Starting 70 Engine 77 Air Cleaner 83 Block Heater 28 41 Break In Recommendations 6 Compartment 77 Coolant Antifreeze 110 Identification 77 Idling 36 Jump Starting 70 Oil 78 110 Oil...

Page 143: ...ds Lubricants and Genuine Parts 110 Fog Lights 20 Fuel 64 66 Adding 66 Diesel 64 66 110 Filter 84 Gauge 11 Requirements 64 Specifications 65 Tank Capacity 109 Gauges Coolant Temperature 11 Fuel 11 Oil Pressure 13 Speedometer 12 Tachometer 11 Voltmeter 14 33 Gear Ranges 48 52 59 Idle Up Feature 37 Information Center Vehicle 21 Instrument Cluster 10 11 Intervention Regeneration Strategy 89 142 INDEX...

Page 144: ...PMS 17 Traction Control 20 Warning Instrument Cluster Description 11 Locks Steering Wheel 6 Maintenance Procedures 78 Maintenance Schedule 114 Manual Transmission 57 Fluid Level Check 101 Lubricant Selection 112 Shift Speeds 59 New Vehicle Break In Period 6 Noise Control Maintenance 105 Tampering Prohibited 106 Noise Emission Warranty 105 107 Odometer 13 Trip 13 Oil Change Indicator 23 115 Oil Cha...

Page 145: ...peration 61 Power Steering Fluid 112 PTO Power Take Off 61 Radiator Cap Coolant Pressure Cap 94 96 Resetting Oil Change Indicator 23 Resetting Perform Service Indicator 116 Seat Belts Reminder 20 Selection of Coolant Antifreeze 94 110 Shifting 44 Automatic Transmission 46 Manual Transmission 57 Signals Turn 11 Speedometer 12 Starting 28 Automatic Transmission 28 Engine Block Heater 28 41 Manual Tr...

Page 146: ... Torque Converter Clutch 51 56 Tow Haul 50 Traction Control 100 Traction Control Light 20 Transfer Case Fluid 112 Transmission Automatic 46 52 Fluid 112 Manual 28 57 Shifting 44 Trip Odometer 13 Turn Signals 11 Viscosity Engine Oil 81 Voltmeter 14 33 Warning Lights Instrument Cluster Description 11 Water Separator Diesel Fuel 84 8 INDEX 145 ...

Page 147: ...Chrysler Group LLC 10D241 226 AB 2nd Edition Printed in U S A ...

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