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RAM Trucks 1500 Owner's Manual

Manual is about: 2016

Summary of Trucks 1500

  • Page 1

    O w n e r ’ s m a n u a l 2 0 1 6 r a m t r u c k d i e s e l s u p p l e m e n t.

  • Page 2: Ram Diesel Supplement

    Ram diesel supplement ram 1500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ram 2500 / 3500 / 4500 / 5500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 index . . . . . . . . ....

  • Page 3: Ram Diesel Supplement

    Ram diesel supplement ram 1500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ram 2500 / 3500 / 4500 / 5500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 index . . . . . . . . ....

  • Page 5: Ram 1500

    Ram 1500

  • Page 7: Table Of Contents

    Table of contents section page 1 introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 2 things to know before starting your vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 3 understanding your inst...

  • Page 9: Introduction

    Introduction contents 䡵 a message from fca us llc . . . . . . . . . . . . .8 1.

  • Page 10

    A message from fca us llc fca us llc welcomes you as a turbocharged diesel- powered truck owner. Your diesel truck will sound, feel, drive, and operate differently from a gasoline-powered truck. It is important that you read and understand this manual. Almost 100% of the heavy trucks in the united s...

  • Page 11

    This information may be used to determine if repair will be covered by new vehicle limited warranty. There is a probability that the use of a “performance chip” will prohibit the engine from starting. In this instance, the vehicle will need to be serviced by a authorized dealer in order to return th...

  • Page 13: Contents

    Things to know before starting your vehicle contents 䡵 remote starting system . . . . . . . . . . . . . .12 ▫ how to use remote start . . . . . . . . . . . . . . . .12 䡵 engine break-in recommendations . . . .13 2.

  • Page 14

    Remote starting system this system uses the remote keyless entry (rke) transmitter to start the engine conve- niently from outside the vehicle while still maintaining security. The system has a range of approximately 300 ft (91 m). Note: • the vehicle must be equipped with an automatic transmission ...

  • Page 15

    • fuel meets minimum requirement • system not disabled from previous remote start event • vehicle security alarm not active • water in fuel indicator light is not illuminated • “wait to start” telltale is not illuminated warning! • do not start or run an engine in a closed garage or confined area. E...

  • Page 16

    Note: light duty operation such as light trailer towing or no load operation will extend the time before the engine is at full efficiency. Reduced fuel economy and power may be seen at this time. The engine oil installed in the engine at the factory is a high-quality energy conserving type lubricant...

  • Page 17: Contents

    Understanding your instrument panel contents 䡵 instrument cluster — base (evic) . . . . .16 䡵 instrument cluster — premium (did) . . .19 䡵 warning and indicator lights . . . . . . . .22 ▫ yellow telltale indicator lights. . . . . . . . . . . . .23 䡵 electronic vehicle information center (evic) . . ....

  • Page 18

    Instrument cluster — base (evic) base evic instrument cluster — if equipped 16 understanding your instrument panel.

  • Page 19

    1. Tachometer • indicates the engine speed in revolutions per minute (rpm x 1000). 2. Electronic vehicle information center (evic) display • when the appropriate conditions exist, this display shows the electronic vehicle information center (evic) messages. Refer to “electronic vehicle infor- mation...

  • Page 20

    • the def gauge may also not immediately update after a refill if the temperature of the def fluid is below 12f (-11c). The def line heater will possibly warm up the def fluid and allow the gauge to update after a period of run time. Under very cold conditions, it is possible that the gauge may not ...

  • Page 21

    Instrument cluster — premium (did) premium did instrument cluster — if equipped 3 understanding your instrument panel 19.

  • Page 22

    1. Tachometer • indicates the engine speed in revolutions per minute (rpm x 1000). 2. Engine coolant temperature • this gauge shows the engine coolant temperature. The gauge pointer will likely show higher tempera- tures when driving in hot weather, up mountain grades, or in heavy stop and go traffi...

  • Page 23

    3. Oil pressure gauge • the pointer should always indicate some oil pres- sure when the engine is running. A continuous high or low reading under normal driving conditions may indicate a lubrication system malfunction. Immedi- ate service should be obtained from an authorized dealer. 4. Speedometer ...

  • Page 24

    Note: • the gauge may take up to five seconds to update after adding a gallon or more of diesel exhaust fluid (def) to the def tank. If you have a fault related to the def system, the gauge may not update to the new level. See your authorized dealer for service. • the def gauge may also not immediat...

  • Page 25

    Yellow telltale indicator lights wait to start light — if equipped yellow telltale light what it means wait to start light the “wait to start” telltale will illuminate for approximately two seconds when the ignition is turned to the run position. It’s duration may be longer based on colder operating...

  • Page 26

    Water in fuel indicator light — if equipped yellow telltale light what it means water in fuel indicator light the “water in fuel indicator light” will illuminate when there is water detected in the fuel filters. If this light remains on, do not start the vehicle before you drain the water from the f...

  • Page 27

    Electronic vehicle information center (evic) the electronic vehicle information center (evic) fea- tures a driver-interactive display that is located in the instrument cluster. This system conveniently allows the driver to select a variety of useful information by pushing the switches mounted on the...

  • Page 28

    Electronic vehicle information center (evic) displays — 3.5” display the evic displays are located in the center portion of the cluster and consists of seven sections: 1. Compass display displays the current direction. For further information, refer to “compass settings” under “customer program- mab...

  • Page 29

    • electronic speed control set this light will turn on when the electronic speed control is set. For further information, refer to “electronic speed control” in “under- standing the features of your vehicle.” • ers gear limit the highest available transmission gear is displayed in the lower right co...

  • Page 30

    Caution! Continuous driving with the transmission tempera- ture warning light illuminated will eventually cause severe transmission damage or transmission failure. Warning! If you continue operating the vehicle when the transmission temperature warning light is illumi- nated you could cause the flui...

  • Page 31

    Note: the “wait to start” telltale may not illuminate if the intake manifold temperature is warm enough. • low diesel exhaust fluid light this telltale will turn on to indicate the diesel exhaust fluid (def) is low. 6. Evic red telltales • door ajar this light will turn on to indicate that one or mo...

  • Page 32

    If jump starting is required, refer to “jump starting procedures” in “what to do in emergencies”. • electronic throttle control (etc) light this light informs you of a problem with the electronic throttle control (etc) system. The light will come on when the ignition is first turned on and remain on...

  • Page 33

    • electric power steering malfunction warning light this telltale is on when the electric power steering is not operating and needs service. • trailer brake disconnected warning light this telltale is on when the trailer brake has been disconnected. 7. Audio/phone information and sub-menu informatio...

  • Page 34

    • unstored messages until run these messages deal primarily with the remote start feature. This message type is displayed until the ignition is in the run state. Examples of this message type are “remote start aborted - door ajar” and “press brake pedal and push button to start”. • five second unsto...

  • Page 35

    Your vehicle has the ability to alert you to additional maintenance required on your vehicle or engine. Refer to the following messages that may be displayed on your electronic vehicle information center (evic): • exhaust filter xx% full safely drive at highway speeds to remedy — this message will b...

  • Page 36

    • exhaust service required — see dealer now — this messages indicates regeneration has been disabled due to a system malfunction. At this point the engine powertrain control module (pcm) will register a fault code, the instrument panel will display a mil light. Caution! See your authorized dealer, a...

  • Page 37

    A single chime. The remaining mileage can be pulled up anytime by way of the “messages” list within the evic/did • engine will not restart in xxxx mi refill def — this message will display when def driving range is less than 200 miles. It is also displayed at 150 miles and 100 miles. Def fluid top o...

  • Page 38

    Authorized dealer and have your vehicle serviced immediately. If not corrected in 50 miles, vehicle will enter the “engine will not restart in xxxmi service def see dealer” warning stage and message. • incorrect def detected see dealer — this message will display if the def system has detected the i...

  • Page 39

    Recommend you drive to your nearest authorized dealer if the message appears while engine is running. • engine will not start service def system see dealer — this message will display when the fault detected is not serviced after the engine will not restart service def system see dealer message is d...

  • Page 40

    • engine will not restart refill def • service def system see dealer • incorrect def detected see dealer • engine will not restart in xxx mi service def see dealer • engine will not restart service def system see dealer oil life reset your vehicle is equipped with an engine oil change indicator syst...

  • Page 41

    6. Push and release the up arrow button to exit the evic screen. Vehicles not equipped with passive entry 1. Without depressing the brake pedal, cycle the ignition to the on/run position (do not start the engine). 2. Push and release the down arrow button to scroll downward through the main menu to ...

  • Page 42

    • trans temperature displays the actual transmission sump temperature. • coolant temp displays the actual coolant temperature. • tire pressure monitor system displays the actual tire pressure. • engine hours displays the actual engine hours. Gauge summary (coolant temp, trans temp, oil temp, oil pre...

  • Page 43

    • down arrow button push and release the down arrow button to scroll downward through the main menu and submenus (fuel economy, trip a, trip b, au- dio, stored messages, screen set up). • right arrow button push and release the right arrow button to access/select the information screens or sub- menu...

  • Page 44

    Mounted on the steering wheel. Refer to “driver infor- mation display– if equipped” in the owner’s manual for further information. Vehicle information (customer information features) vehicle information submenus • battery voltage displays the actual battery voltage. • fuel filter life displays the l...

  • Page 45

    • up arrow button push and release the up arrow button to scroll upward through the main menu and sub- menus (fuel economy, trip a, trip b, audio, stored messages, screen set up). • down arrow button push and release the down arrow button to scroll downward through the main menu and submenus (fuel e...

  • Page 46

    Oil life reset your vehicle is equipped with an engine oil change indicator system. The “oil change required” message will flash in the did display for approximately 10 seconds after a single chime has sounded, to indicate the next scheduled oil change interval. The engine oil change indicator syste...

  • Page 47

    4. Push and hold the right arrow button for one second to access the ” oil life reset” screen. 5. Push and release the down arrow button to select “yes”, then push and release the right arrow button to select reset of the oil life. 6. Push and release the up arrow button to exit the did screen. Note...

  • Page 48

    The driver information display (did) display is located in the center portion of the cluster and consists of eight sections: 1. Main screen — the inner ring of the display will illuminate in grey under normal conditions, yellow for non critical warnings, red for critical warnings and white for on de...

  • Page 49

    The main display area will normally display the main menu or the screens of a selected feature of the main menu. The main display area also displays “pop up” messages that consist of approximately 60 possible warn- ing or information messages. These pop up messages fall into several categories: • fi...

  • Page 50

    Diesel indicator lights this area will show reconfigurable amber telltales that relate to your diesel. These telltales include: note: “refer to your om on dvd for additional telltale information” water in fuel indicator light the “water in fuel indicator light” will illumi- nate when there is water ...

  • Page 51

    Managed by the powertrain control module (pcm). The pcm manages engine combustion to allow the exhaust system’s catalyst to trap and burn particulate matter (pm) pollutants, with no input or interaction on your part. Warning! A hot exhaust system can start a fire if you park over materials that can ...

  • Page 52

    Trapped pm. If this occurs, the “exhaust filter xx% full safely drive at highway speeds to remedy” message will be displayed in the did. 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 ...

  • Page 53

    Corrected and a dealer service is not performed, exten- sive exhaust after-treatment damage can occur. To correct this condition it will be necessary to have your vehicle serviced by your local authorized dealer. Caution! See your authorized dealer, as damage to the exhaust system could occur soon w...

  • Page 54

    Mile remaining distances. The def low telltale will be on continuously until def fluid is topped off. • engine will not restart refill def — this message will display when the def driving range is less than 1 mile, def fluid top off is required or the engine will not restart. The message will be dis...

  • Page 55

    • engine will not restart in xxx mi service def see dealer — this message is first displayed if the fault detected is not serviced after 50 miles of operation. It is also displayed at 150 miles 125 miles and 100 miles. System service is required within the displayed mile- age. The message will be di...

  • Page 56

    Did displays when the appropriate conditions exist, the did displays the following messages: • system setup unavailable – vehicle not in park • system setup unavailable – vehicle in motion • exhaust filter full safely drive at highway speeds to remedy • exhaust filter xx% full – power reduced see de...

  • Page 57

    Screen setup push and release the up or down ar- row button until the screen setup display icon is highlighted in the did. Push and release the right arrow button to enter the screen setup sub- menu. The screen setup feature allows you to change what information is displayed in the instrument cluste...

  • Page 58

    Settings options 2 upper right • none • compass • outside temp. (default) • time • range to empty • average mpg (not available for cng models) • current mpg (not available for cng models) • trip a • trip b • trailer trip • trailer brake gain 56 understanding your instrument panel.

  • Page 59

    Settings options 3 lower left • none (default) • compass • outside temp. • time • range to empty • average mpg (not available for cng models) • current mpg (not available for cng models) • trailer brake gain 4 lower right • none (default) • compass • outside temp. • time • range to empty • average m...

  • Page 60

    Settings options 5 upper gauge • none (default) • trans temp. • oil temp. • oil life • fuel filter life (hd diesel only) • battery voltage (diesel & cng only) • exhaust brake (hd diesel only) • turbo boost (hd diesel only) • current mpg (not available for cng models) • trailer brake gain 58 understa...

  • Page 61

    Settings options 6 lower gauge • none (default) • trans temp. • oil temp. • oil life • fuel filter life (hd diesel only) • battery voltage (diesel & cng only) • exhaust brake (hd diesel only) • turbo boost (hd diesel only) • current mpg (not available for cng models) • trailer brake gain 7 odometer ...

  • Page 63: Starting And Operating

    Starting and operating contents 䡵 starting procedures . . . . . . . . . . . . . . . . .63 ▫ normal starting . . . . . . . . . . . . . . . . . . . . . . .64 ▫ automatic transmission . . . . . . . . . . . . . . . . .64 ▫ keyless enter-n-go . . . . . . . . . . . . . . . . . . . .65 ▫ extreme cold weath...

  • Page 64

    ▫ bulk fuel storage — diesel fuel . . . . . . . . . . .83 ▫ diesel exhaust fluid storage . . . . . . . . . . . . . .83 ▫ adding diesel exhaust fluid . . . . . . . . . . . . . .84 62 starting and operating.

  • Page 65

    Starting procedures before starting your vehicle, adjust your seat, both inside and outside mirrors, and fasten your seat belts. The starter is allowed to crank for up to 30-second intervals. Waiting a few minutes between such intervals will protect the starter from overheating. Warning! • before ex...

  • Page 66

    Note: engine start up in very low ambient temperature could result in evident white smoke. This condition will disappear as the engine warms up. Caution! • the engine is allowed to crank as long as 30 seconds. If the engine fails to start during this period, please wait at least two minutes for the ...

  • Page 67

    Keyless enter-n-go this feature allows the driver to oper- ate the ignition switch with the push of a button, as long as the remote start/keyless enter-n-go key fob is in the passenger compartment. Normal starting procedure — keyless enter-n-go observe the instrument panel cluster lights when starti...

  • Page 68

    3. The system will automatically engage the starter to crank the engine. If the vehicle fails to start, the starter will disengage automatically after 25 seconds. 4. If you wish to stop the cranking of the engine prior to the engine starting, push the button again. 5. Check that the oil pressure war...

  • Page 69

    Starting fluids the engine is equipped with a glow plug preheating system. If the instructions in this manual are followed, the engine should start in all conditions and no type of starting fluid should be used. Warning! • do not leave children or animals inside parked vehicles in hot weather. Inter...

  • Page 70

    Normal operation observe the following when the diesel engine is operat- ing. • all message center lights are off. • malfunction indicator light (mil) is off. • engine oil pressure telltale is not illuminated. • voltmeter operation: the voltmeter may show a gauge fluctuation at various engine temper...

  • Page 71

    Note: • use of climatized ultra low sulfur diesel fuel or number 1 ultra low sulfur diesel fuel results in a noticeable decrease in fuel economy. • climatized ultra low sulfur diesel fuel is a blend of number 2 ultra low sulfur and number 1 ultra low sulfur diesel fuels which reduces the temperature...

  • Page 72

    Cycling frequently, increase the size of the opening in the winter front. A suitable cold weather cover is available from your mopar dealer. Engine warm-up avoid full throttle operation when the engine is cold. When starting a cold engine, bring the engine up to operating speed slowly to allow the o...

  • Page 73

    Driving condition load turbocharger temperature idle time (min.) before engine shutdown stop and go empty cool none stop and go medium 0.5 highway speeds medium warm 1.0 city traffic maximum gcwr 1.5 highway speeds maximum gcwr 2.0 uphill grade maximum gcwr hot 2.5 note: under certain conditions the...

  • Page 74

    Do not operate the engine with low oil pressure if the low oil pressure warning light turns on while driving, stop the vehicle and shut down the engine as soon as possible. A chime will sound when the light turns on. Note: do not operate the vehicle until the cause is corrected. This light does not ...

  • Page 75

    Engine block heater — if equipped the engine block heater warms engine coolant and permits quicker starts in cold weather. Connect the heater cord to a ground-fault interrupter protected 110–115 volt ac electrical outlet with a grounded, three-wire exten- sion cord. Its use is recommended for enviro...

  • Page 76

    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...

  • Page 77

    Note: • if you accidentally fill the fuel tank with gasoline on your diesel vehicle, do not start the engine. Damage to the engine and fuel system could occur. Please call your authorized dealer for service. • a maximum blend of 5% biodiesel meeting astm specification d-975 may be used with your die...

  • Page 78

    Caution! Failure to comply with oil change requirements for vehicles operating on biodiesel blends between 6% and 20% (b6–b20) will result in premature engine wear. Such wear is not covered by the new vehicle limited warranty. Biodiesel is a fuel produced from renewable resources typically derived f...

  • Page 79

    Fuel quality — must comply with astm standards the quality of biodiesel fuel may vary widely. Only fuel produced by a bq9000 supplier to the following specifi- cations may be blended to meet biodiesel blend b6 – b20 fuel meeting astm specification d-7467: • petrodiesel fuel meeting astm specificatio...

  • Page 80

    Biodiesel fuel filter change intervals the use of biodiesel requires intervals shorter than the outlined 30,000 miles (48 280 km) and must not exceed the suggested schedule. When operating on biodiesel between 6% and 20%, fuel filter replacement intervals must not exceed 20,000 miles (40 233 km). No...

  • Page 81

    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-h...

  • Page 82

    Adding fuel — 1500 diesel models 1. Open the fuel filler door. Note: there is no fuel filler cap. A flapper door inside the filler pipe seals the system. 2. Insert the fuel nozzle fully into the filler pipe – the nozzle opens and holds the flapper door while refuel- ing. 3. Fill the vehicle with fue...

  • Page 83

    1. Retrieve fuel funnel from the jack kit located under the front passenger seat. 2. Insert funnel into same filler pipe opening as the fuel nozzle. Diesel fuel and def fluid filler door fuel fill funnel location 1500 models 4 starting and operating 81.

  • Page 84

    Note: ensure funnel is inserted fully to hold flapper door open. 3. Pour fuel into funnel opening. 4. Remove funnel from filler pipe, clean off prior to putting back in the jack kit. Caution! To avoid fuel spillage and overfilling, do not “top off” the fuel tank after filling. Warning! • never have ...

  • Page 85

    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 st...

  • Page 86

    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...

  • Page 87

    2. Insert def fill adapter/nozzle into def tank filler neck. Note: • the def gauge may take up to five seconds to update after adding a gallon or more of diesel exhaust fluid (def) to the def tank. If you have a fault related to the def system, the gauge may not update to the new level. See your aut...

  • Page 88

    Caution! • to avoid def spillage, and possible damage to the def tank from overfilling, do not “top off” the def tank after filling. • do not overfill. Def will freeze below 12ºf (-11ºc). The def system is designed to work in temperatures below the def freezing point, how- ever, if the tank is overf...

  • Page 89

    4. Reinstall cap onto def tank. Filling the def tank in cold climates since def will begin to freeze at 12°f (-11°c), your vehicle is equipped with an automatic def heating system. This allows the def injection system to operate properly at temperatures below 12°f (-11°c). If your vehicle is not in ...

  • Page 91: Maintaining Your Vehicle

    Maintaining your vehicle contents 䡵 engine compartment — 3.0l diesel . . . . .90 䡵 maintenance procedures . . . . . . . . . . . .91 ▫ engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . .92 ▫ engine air cleaner filter . . . . . . . . . . . . . . . .94 ▫ draining fuel/water separator filte...

  • Page 92

    Engine compartment — 3.0l diesel 1 — air cleaner filter 5 — battery 2 — engine oil dipstick 6 — power distribution center (pdc) 3 — engine oil fill 7 — washer fluid reservoir 4 — brake fluid reservoir 8 — engine coolant 90 maintaining your vehicle.

  • Page 93

    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 futu...

  • Page 94

    Engine oil engine oil selection for best performance and maximum protection under all types of operating conditions, the manufacturer recom- mends engine oils that meet the requirements of fca material standard ms-11106, and that are approved to acea c3. Checking oil level to assure proper lubricati...

  • Page 95

    Mark. The total capacity from the min mark to the max mark is 1.3 qts (1.2 l). Caution! Overfilling or underfilling the crankcase will cause oil aeration or loss of oil pressure. This could damage your engine. Note: it is possible for your oil level to be slightly higher than a previous check. This ...

  • Page 96

    Recommended for all operating temperatures. This en- gine oil improves low temperature starting and vehicle fuel economy. Materials added to engine oil the manufacturer strongly recommends against the ad- dition of any additives (other than leak detection dyes) to the engine oil. Engine oil is an en...

  • Page 97

    Warning! The air induction system (air cleaner, hoses, etc.) provides a measure of protection. Do not remove the air induction system (air cleaner, hoses, etc.) unless such removal is necessary for repair or maintenance. Make sure that no one is near the engine compart- ment before starting the vehi...

  • Page 98

    2. Lift the air cleaner cover to access the air cleaner filter. 3. Remove the air cleaner filter element from the housing assembly. 3.0 diesel air cleaner filter cover 1 — air cleaner filter cover 2 — spring clips open air cleaner filter assembly 1 — air cleaner cover 2 — air cleaner filter 96 maint...

  • Page 99

    Engine air cleaner filter installation note: inspect and clean the housing if dirt or debris is present before replacing the air filter element. 1. Install the air cleaner filter element into the housing assembly with the air cleaner filter inspection surface facing downward. 2. Install the air clea...

  • Page 100

    Caution! • do not drain the fuel/water separator filters when the engine is running. • diesel fuel will damage blacktop paving surfaces. Drain the filters 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...

  • Page 101

    Caution! If the “water in fuel indicator light” remains on, do not start the engine before you drain water from the fuel filters 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 in the on position, there m...

  • Page 102

    If more than two ounces or 60 milliliters of fuel have been drained, follow the directions for “priming if the engine has run out of fuel.” underbody mounted fuel filter replacement note: using a fuel filter that does not meet the manu- facturer’s filtration and water separating requirements can sev...

  • Page 103

    3. Open the water drain valve, and let any accumulated water drain. 4. Close the water drain valve. 5. Remove bottom cover using a strap wrench. Rotate counterclockwise for removal. Remove the used o-ring and discard it. 6. Remove the used filter cartridge from the housing and dispose of it accordin...

  • Page 104

    Caution! The starter motor will engage for approximately 30 seconds at a time. Allow two minutes between crank- ing 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 ...

  • Page 105

    Intervention regeneration strategy — message process flow this engine meets all required diesel engine emissions standards. To achieve these emissions standards, your vehicle is equipped with a state-of-the-art engine and exhaust system. These systems are seamlessly integrated into your vehicle and ...

  • Page 106

    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”...

  • Page 107

    Spraying water from a garden hose vertically down the face of the a/c condenser (if equipped) or the back of the radiator core. Check the engine cooling system hoses for brittle rubber, cracking, tears, cuts and tightness of the connection at the coolant recovery bottle and radiator. Inspect the ent...

  • Page 108

    Caution! • mixing of engine coolant (antifreeze) other than specified organic additive technology (oat) en- gine coolant (antifreeze), may result in engine damage and may decrease corrosion protection. Organic additive technology (oat) engine cool- ant is different and should not be mixed with hybri...

  • Page 109

    Important that you use the same engine coolant (oat coolant conforming to ms.90032) throughout the life of your vehicle. Please review these recommendations for using organic additive technology (oat) engine coolant (antifreeze) that meets the requirements of fca material standard ms.90032. When add...

  • Page 110

    • mixing engine coolant (antifreeze) types is not recom- mended and can result in cooling system damage. If hoat and oat coolant are mixed in an emergency, have a authorized dealer drain, flush, and refill with oat coolant (conforming to ms.90032) as soon as possible. Cooling system pressure cap the...

  • Page 111

    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. Points to remember note: when the vehicle is stopped after a few miles/ kilometers of operation...

  • Page 112

    • 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 engine coolant (antifreeze) performance, poor gas mileage, and increased emis- sions. Charge air cooler — inter-cooler...

  • Page 113

    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. Warn...

  • Page 114

    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 lowe...

  • Page 115

    Fluid capacities u.S. Metric fuel (approximate) 3.0l diesel engine 26 gallons 98.5 liters diesel exhaust fluid tank 8 gallons 30.3 liters engine oil with filter 3.0l liter diesel engine (sae 5w-30 synthetic, api certified low ash) 10.5 quarts 10 liters cooling system 3.0l turbo diesel engine (mopar ...

  • Page 116

    Fluids, lubricants and genuine parts engine component fluid, lubricant, or genuine part engine coolant we recommend you use mopar antifreeze/coolant 10 year/150,000 mile formula oat (organic additive technology). Engine oil only use acea c3 5w-30 synthetic low ash engine oil meeting fca material sta...

  • Page 117

    Component fluid, lubricant, or genuine part fuel selection 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...

  • Page 118

    Note: 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 ...

  • Page 119

    Caution! (continued) • do not use water alone or alcohol-based engine coolant (antifreeze) products. Do not use additional rust inhibitors or antirust products, as they may not be compatible with the radiator engine coolant and may plug the radiator. • this vehicle has not been designed for use with...

  • Page 120

    Chassis component fluid, lubricant, or genuine part automatic transmission only use mopar zf 8&9 speed atf automatic trans- mission fluid or equivalent. Failure to use the correct fluid may affect the function or performance of your transmission. Transfer case we recommend you use mopar bw44–44 tran...

  • Page 121: Maintenance Schedule

    Maintenance schedule contents 䡵 maintenance schedule . . . . . . . . . . . . .120 ▫ maintenance chart — diesel fuel up to b5 biodiesel . . . . . . . . . . . . . . . . . . . . . . . . . . .122 ▫ additional maintenance — b6 to b20 biodiesel . . . . . . . . . . . . . . . . . . . .125 6.

  • Page 122

    Maintenance schedule your vehicle is equipped with an automatic oil change indicator system. The oil change indicator system will remind you that it is time to take your vehicle in for scheduled maintenance. Based on engine operation conditions, the oil change indicator message will illuminate. This...

  • Page 123

    Required maintenance refer to the maintenance schedules on the following pages for required maintenance. At every oil change interval as indicated by oil change indicator system: • change oil and filter. • completely fill the diesel exhaust fluid tank. • drain water from fuel filter assembly. • rota...

  • Page 124

    Maintenance chart — diesel fuel up to b5 biodiesel mileage or time passed (whichever comes first) 10,000 20,000 30,000 40,000 50,000 60,000 70,000 80,000 90,000 100,000 1 10,000 120,000 130,000 140,000 150,000 or years: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 or kilometers: 16,000 32,000 48,000 64,000 8...

  • Page 125

    Mileage or time passed (whichever comes first) 10,000 20,000 30,000 40,000 50,000 60,000 70,000 80,000 90,000 100,000 1 10,000 120,000 130,000 140,000 150,000 or years: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 or kilometers: 16,000 32,000 48,000 64,000 80,000 96,000 1 12,000 128,000 144,000 160,000 176,0...

  • Page 126

    Mileage or time passed (whichever comes first) 10,000 20,000 30,000 40,000 50,000 60,000 70,000 80,000 90,000 100,000 1 10,000 120,000 130,000 140,000 150,000 or years: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 or kilometers: 16,000 32,000 48,000 64,000 80,000 96,000 1 12,000 128,000 144,000 160,000 176,0...

  • Page 127

    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 me- chanic. • failure to properly inspect and m...

  • Page 128

    Additional maintenance chart — b6 to b20 biodiesel mileage or time passed (whichever comes first) 10,000 20,000 30,000 40,000 50,000 60,000 70,000 80,000 90,000 100,000 1 10,000 120,000 130,000 140,000 150,000 or years: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 or kilometers: 16,000 32,000 48,000 64,000 8...

  • Page 129

    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 me- chanic. • failure to properly inspect and m...

  • Page 131

    Ram 2500 / 3500 / 4500 / 5500

  • Page 133: Table Of Contents

    Table of contents section page 1 introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 2 things to know before starting your vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 3 understanding the featur...

  • Page 135: Introduction

    Introduction contents 䡵 a message from fca us llc . . . . . . . . . . .134 1.

  • Page 136

    A message from fca us llc fca us llc and cummins welcome you as a cummins turbocharged diesel-powered truck owner. Your diesel truck will sound, feel, drive, and operate differently from a gasoline-powered truck. It is important that you read and understand this manual. Almost 100% of the heavy duty...

  • Page 137

    When it comes to service, remember that your authorized dealer knows your vehicle best, has factory-trained tech- nicians and genuine mopar® parts, and cares about your satisfaction. 1 introduction 135.

  • Page 139: Contents

    Things to know before starting your vehicle contents 䡵 remote starting system — if equipped . . . . . . . . . . . . . . . . . . . . . . . . .138 ▫ how to use remote start . . . . . . . . . . . . . . .138 䡵 engine break-in recommendations . . .141 2.

  • Page 140

    Remote starting system — if equipped this system uses the remote keyless entry (rke) transmitter to start the engine conve- niently from outside the vehicle while still maintaining security. The system has a range of approximately 300 ft (91 m). Note: • the vehicle must be equipped with an automatic...

  • Page 141

    • wait to start light is not illuminated warning! • do not start or run an engine in a closed garage or confined area. Exhaust gas contains carbon mon- oxide (co) which is odorless and colorless. Carbon monoxide is poisonous and can cause serious in- jury or death when inhaled. • keep remote keyless...

  • Page 142

    Note: • the park lamps will turn on and remain on during remote start mode. • for security, power window and power sunroof op- eration (if equipped) are disabled when the vehicle is in the remote start mode. • the engine can be started two consecutive times (two 15-minute cycles) with the rke transm...

  • Page 143

    Remote start comfort systems — if equipped when remote start is activated, the heated steering wheel, and driver heated seat features will automatically turn on in cold weather. In warm weather, the driver vented seat feature will automatically turn on when the remote start is activated. These featu...

  • Page 144

    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 turbo- charged diesel engine, engine run-in is enhanced by loaded operating conditions which allow the engine parts to achieve final fi...

  • Page 145: Contents

    Understanding the features of your vehicle contents 䡵 electronic speed control . . . . . . . . . . .144 ▫ to activate . . . . . . . . . . . . . . . . . . . . . . . . . .145 ▫ to set a desired speed . . . . . . . . . . . . . . . . .145 ▫ to deactivate . . . . . . . . . . . . . . . . . . . . . . . .14...

  • Page 146

    Electronic speed control when engaged, the electronic speed control takes over accelerator operations at speeds greater than 25 mph (40 km/h). The electronic speed control buttons are located on the right side of the steering wheel. Electronic speed control switches 1 — on/off 3 — set - 2 — res + 4 ...

  • Page 147

    Note: in order to ensure proper operation, the elec- tronic speed control system has been designed to shut down if multiple speed control functions are operated at the same time. If this occurs, the electronic speed control system can be reactivated by pushing the electronic speed control on/off but...

  • Page 148

    To deactivate a soft tap on the brake pedal, pushing the cancel button, or normal brake pressure while slowing the vehicle will deactivate the electronic speed control with- out erasing the set speed from memory. Pushing the on/off button or turning the ignition switch off erases the set speed from ...

  • Page 149

    • if the button is continually pushed, the set speed will continue to increase until the button is released, then the new set speed will be established. To decrease speed when the electronic speed control is set, you can de- crease speed by pushing the set (-) button. The drivers preferred units can...

  • Page 150

    Note: the electronic speed control system maintains speed up and down hills. A slight speed change on moderate hills is normal. On steep hills, a greater speed loss or gain may occur so it may be preferable to drive without electronic speed control. Warning! Electronic speed control can be dangerous...

  • Page 151: Contents

    Understanding your instrument panel contents 䡵 instrument cluster — base (evic) . . . . .150 䡵 instrument cluster — premium (did) . .153 䡵 warning and indicator lights . . . . . . .156 ▫ yellow telltale indicator lights . . . . . . . . . . . .157 䡵 electronic vehicle information center (evic) . . . ...

  • Page 152

    Instrument cluster — base (evic) base evic instrument cluster — if equipped 150 understanding your instrument panel.

  • Page 153

    1. Tachometer • indicates the engine speed in revolutions per minute (rpm x 1000). 2. Electronic vehicle information center (evic) display • when the appropriate conditions exist, this display shows the electronic vehicle information center (evic) messages. Refer to “electronic vehicle infor- mation...

  • Page 154

    • the def gauge may also not immediately update after a refill if the temperature of the def fluid is below 12f (-11c). The def line heater will possibly warm up the def fluid and allow the gauge to update after a period of run time. Under very cold conditions, it is possible that the gauge may not ...

  • Page 155

    Instrument cluster — premium (did) premium did instrument cluster — if equipped 4 understanding your instrument panel 153.

  • Page 156

    1. Tachometer • indicates the engine speed in revolutions per minute (rpm x 1000). 2. Engine coolant temperature • this gauge shows the engine coolant temperature. The gauge pointer will likely show higher tempera- tures when driving in hot weather, up mountain grades, or in heavy stop and go traffi...

  • Page 157

    Or low reading under normal driving conditions may indicate a lubrication system malfunction. Immedi- ate service should be obtained from an authorized dealer. 4. Speedometer • indicates vehicle speed. 5. Fuel gauge • the pointer shows the level of fuel in the fuel tank when the ignition switch is i...

  • Page 158

    • the def gauge may also not immediately update after a refill if the temperature of the def fluid is below 12f (-11c). The def line heater will possibly warm up the def fluid and allow the gauge to update after a period of run time. Under very cold conditions, it is possible that the gauge may not ...

  • Page 159

    Yellow telltale indicator lights wait to start light — if equipped yellow telltale light what it means wait to start light the “wait to start” telltale will illuminate for approximately two seconds when the ignition is turned to the run position. It’s duration may be longer based on colder operating...

  • Page 160

    Water in fuel indicator light — if equipped yellow telltale light what it means water in fuel indicator light the “water in fuel indicator light” will illuminate when there is water detected in the fuel filters. If this light remains on, do not start the vehicle before you drain the water from the f...

  • Page 161

    Electronic vehicle information center (evic) the electronic vehicle information center (evic) fea- tures a driver-interactive display that is located in the instrument cluster. This system conveniently allows the driver to select a variety of useful information by pushing the switches mounted on the...

  • Page 162

    • exhaust filter full – power reduced see dealer — if equipped • exhaust service required – see dealer now — if equipped • exhaust system – filter xx% full service required see dealer — if equipped • exhaust system – regeneration in process exhaust filter xx% full — if equipped • exhaust system – re...

  • Page 163

    Vehicle information (customer information features) vehicle information submenus • battery voltage displays the actual battery voltage. • fuel filter life displays the life of the fuel filter. • oil pressure displays the actual oil pressure. • oil temperature displays the actual oil temperature. • t...

  • Page 164

    • up arrow button push and release the up arrow button to scroll upward through the main menu and sub- menus (fuel economy, trip a, trip b, audio, stored messages, screen set up). • down arrow button push and release the down arrow button to scroll downward through the main menu and submenus (fuel e...

  • Page 165

    Diesel indicator lights water in fuel indicator light the “water in fuel indicator light” will illu- minate when there is water detected in the fuel filters. If this light remains on, do not start the vehicle before you drain the water from the fuel filters to prevent engine damage. Refer to “mainte...

  • Page 166

    • engine power reduced up to 30 sec (seconds) during warmup — this message will display during start up when the ambient temperature is between -10° f (-23° c) and -25 f (-32° c). • engine power reduced up to 2 min (minutes) during warmup — this message will display during start up when the ambient ...

  • Page 167

    Your vehicle has the ability to alert you to additional maintenance required on your vehicle or engine. Refer to the following messages that may be displayed on your evic or did: • perform service — your vehicle will require emissions maintenance at a set interval. To help remind you when this maint...

  • Page 168

    • exhaust system — regeneration in process exhaust filter xx% full — indicates that the diesel particulate filter (dpf) is self-cleaning. Maintain your current driving condition until regeneration is completed. • exhaust system — regeneration completed — this message indicates that the diesel partic...

  • Page 169

    Diesel exhaust fluid (def) warning messages your vehicle will begin displaying warning messages when the def level reaches a driving range of approxi- mately 200 miles (322 km). If the following warning message sequence is ignored, your vehicle may be lim- ited to a maximum speed of 5 mph (8 km/h) u...

  • Page 170

    • add a minimum of 2 gallons (9.5 liters) of def to the tank in order to avoid vehicle operation at a maximum speed of 5 mph (8 km/h). Note: a minimum of 2 gallons (9.5 liters) may be required to restore normal vehicle operation. Although the vehicle will start normally and can be placed in gear aft...

  • Page 171

    Reaches zero unless the vehicle is serviced. We recom- mend you drive to your nearest authorized dealer and have your vehicle serviced immediately. Note: under some circumstances this mileage counter may start with a value of less than 150 miles (241 km). For example, if recurring faults are detecte...

  • Page 172

    Note: when this message is displayed, the engine can still be started. However, the vehicle will only operate at a maximum speed of 5 mph. Ram active air system your vehicle is equipped with an advanced ram active air system that provides enhanced performance, espe- cially when towing under demandin...

  • Page 173

    Vehicles not equipped with passive entry 1. Without pressing the brake pedal, cycle the ignition to the on/run position (do not start the engine.) 2. Press and release the down arrow button to scroll downward through the main menu to “vehicle info”. 3. Press and release the right arrow button to acc...

  • Page 174

    3. Push and release the right arrow button to access the ”vehicle info” screen, then scroll up or down to select “oil life.” 4. Push and hold the right arrow button to select “reset”. 5. Push and release the right arrow button to select “no” or “yes” to reset the oil life to 100%. 6. Push and releas...

  • Page 175

    Driver information display (did) — 7” display the driver information display (did) display is located in the center portion of the cluster and consists of eight sections: 1. Main screen — the inner ring of the display will illuminate in grey under normal conditions, yellow for non critical warnings,...

  • Page 176

    9. Selectable gauge (trans temp, oil temp, oil life, trailer brake, current mpg, fuel filter life, turbo boost, exhaust brake, battery voltage) 10. Main menu items (digital speedometer, vehicle info, fuel economy, trip a, trip b, trailer tow, audio, stored messages, screen setup, vehicle settings) 1...

  • Page 177

    • unstored messages until run these messages deal primarily with the remote start feature. This message type is displayed until the ignition is in the run state. Examples of this message type are “remote start aborted - door ajar” and “press brake pedal and push button to start”. • five second unsto...

  • Page 178

    Note: the “wait to start” telltale may not illuminate if the intake manifold temperature is warm enough. Low diesel exhaust fluid light this telltale will turn on to indicate the diesel exhaust fluid (def) is low. Cold ambient derate mode messages the vehicle will display messages when a derate (eng...

  • Page 179

    Engine and exhaust system. These systems are seamlessly integrated into your vehicle and managed by the pow- ertrain control module (pcm). The pcm manages en- gine combustion to allow the exhaust system’s catalyst to trap and burn particulate matter (pm) pollutants, with no input or interaction on y...

  • Page 180

    Remove the trapped pm. If this occurs, the “exhaust filter xx% full safely drive at highway speeds to remedy” message will be displayed in the did. 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...

  • Page 181

    Corrected and a dealer service is not performed, exten- sive exhaust after-treatment damage can occur. To correct this condition it will be necessary to have your vehicle serviced by your local authorized dealer. Caution! See your authorized dealer, as damage to the exhaust system could occur soon w...

  • Page 182

    Mile remaining distances. The def low telltale will be on continuously until def fluid is topped off. • engine will not restart refill def — this message will display when the def driving range is less than 1 mile, def fluid top off is required or the engine will not restart. The message will be dis...

  • Page 183

    Note: a minimum of 2 gallons (9.5 liters) may be required to restore normal vehicle operation. Although the vehicle will start normally and can be placed in gear after this message has been initially displayed, extreme caution should be utilized since the vehicle will only be capable of maneuvering ...

  • Page 184

    Reaches zero unless the vehicle is serviced. We recom- mend you drive to your nearest authorized dealer and have your vehicle serviced immediately. Note: under some circumstances this mileage counter may start with a value of less than 150 miles (241 km). For example, if recurring faults are detecte...

  • Page 185

    Be continuously displayed. The message will be ac- companied by a single chime. Your malfunction indi- cator light will be continuously illumined. We highly recommend you drive to your nearest authorized dealer if the message appears while engine is running. Note: when this message is displayed, the...

  • Page 186

    3. Press and release the right arrow button to access the ”fuel filter life” screen. 4. Press and hold the right arrow button for one second to access the reset confirmation screen. 5. Press and release the up or down arrow button to select “yes” or “no” then press and hold the right arrow button to...

  • Page 187

    Screen setup push and release the up or down ar- row button until the screen setup display icon is highlighted in the did. Push and release the right arrow button to enter the screen setup sub- menu. The screen setup feature allows you to change what information is displayed in the instrument cluste...

  • Page 188

    Settings options 2 upper right • none • compass • outside temp. (default) • time • range to empty • average mpg (not available for cng models) • current mpg (not available for cng models) • trip a • trip b • trailer trip • trailer brake gain 186 understanding your instrument panel.

  • Page 189

    Settings options 3 lower left • none (default) • compass • outside temp. • time • range to empty • average mpg (not available for cng models) • current mpg (not available for cng models) • trailer brake gain 4 lower right • none (default) • compass • outside temp. • time • range to empty • average m...

  • Page 190

    Settings options 5 upper gauge • none (default) • trans temp. • oil temp. • oil life • fuel filter life (hd diesel only) • battery voltage (diesel & cng only) • exhaust brake (hd diesel only) • turbo boost (hd diesel only) • current mpg (not available for cng models) • trailer brake gain 188 underst...

  • Page 191

    Settings options 6 lower gauge • none (default) • trans temp. • oil temp. • oil life • fuel filter life (hd diesel only) • battery voltage (diesel & cng only) • exhaust brake (hd diesel only) • turbo boost (hd diesel only) • current mpg (not available for cng models) • trailer brake gain 7 odometer ...

  • Page 192

    Oil life reset your vehicle is equipped with an engine oil change indicator system. The “oil change required” message will flash in the did display for approximately 10 seconds after a single chime has sounded, to indicate the next scheduled oil change interval. The engine oil change indicator syste...

  • Page 193

    4. Push and hold the right arrow button for one second to access the ” oil life reset” screen. 5. Push and release the down arrow button to select “yes”, then push and release the right arrow button to select reset of the oil life. 6. Push and release the up arrow button to exit the did screen. Note...

  • Page 195: Starting And Operating

    Starting and operating contents 䡵 starting procedures . . . . . . . . . . . . . . . .196 ▫ manual transmission — if equipped . . . . . . .196 ▫ automatic transmission — if equipped . . . . .197 ▫ keyless enter-n-go — if equipped . . . . . . . .197 ▫ extreme cold weather . . . . . . . . . . . . . . ....

  • Page 196

    ▫ cooling system tips — automatic transmission . . . . . . . . . . . . . . . . . . . . . . . . .215 䡵 engine block heater — if equipped . . .217 ▫ block heater usage . . . . . . . . . . . . . . . . . . . .217 䡵 diesel exhaust brake (engine braking) . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 197

    ▫ fuel filler cap . . . . . . . . . . . . . . . . . . . . . . .252 ▫ avoid using contaminated fuel . . . . . . . . . . .252 ▫ bulk fuel storage — diesel fuel . . . . . . . . . .252 ▫ diesel exhaust fluid storage. . . . . . . . . . . . . .253 ▫ adding diesel exhaust fluid . . . . . . . . . . . . .254...

  • Page 198

    Starting procedures before starting your vehicle, adjust your seat, adjust both inside and outside mirrors, and fasten your seat belts. The starter should not be operated for more than 15- second intervals. Waiting a few minutes between such intervals will protect the starter from overheating. Warni...

  • Page 199

    Starting the vehicle. This vehicle is equipped with a clutch interlocking ignition system. It will not start unless the clutch is fully pressed. Automatic transmission — if equipped start the engine with the transmission in the neutral or park position. Apply the brake before shifting to any driving...

  • Page 200

    4. If you wish to stop the cranking of the engine prior to the engine starting, remove your foot from the brake pedal and push the button again. Note: • normal starting of either a cold or a warm engine is obtained without pumping or pressing the accelerator pedal. • under cold weather conditions, t...

  • Page 201

    4. If the gear selector is in neutral, push and release the engine start/stop button with the vehicle speed below 5mph (8 km/h) before the engine will shut off. The ignition switch position will remain in the acc position. Note: if the ignition switch is left in the acc or run (engine not running) p...

  • Page 202

    Keyless enter-n-go starting procedure — engine manifold air temperature 0° f to 66° f (–18° c to 19° c) note: the temperature displayed in the electronic vehicle information center (evic) or driver information display (did) does not necessarily reflect the engine manifold air temperature. Refer to “...

  • Page 203

    Caution! If the “water in fuel indicator light” remains on, do not start engine before you drain the water from the fuel filters to avoid engine damage. Refer to “maintenance procedures/draining fuel/water sepa- rator filter” in “maintaining your vehicle” for fur- ther information. 4. After the engi...

  • Page 204

    Ignition switch to the off position for at least five seconds and then back on. Repeat steps 1 through 7 of “keyless enter-n-go starting procedure – engine manifold air temperature below 66° f (19° c).” extreme cold weather the cummins diesel engine is equipped with several features designed to assi...

  • Page 205

    3. Turn the ignition switch to the on position and watch the instrument panel cluster lights. Caution! If the “water in fuel indicator light” remains on, do not start the engine before you drain the water from the fuel filters to avoid engine damage. Refer to “maintenance procedures/draining fuel/wa...

  • Page 206

    Starting procedure — engine manifold air temperature 0°f to 66°f (–18°c to 19°c) note: the temperature displayed in the electronic vehicle information center (evic) or driver information display (did) does not necessarily reflect the engine manifold air temperature. Refer to “electronic vehicle info...

  • Page 207

    Caution! Do not crank engine for more than 15 seconds at a time or starter motor damage may result. Turn the ignition switch to the off position and wait at least two minutes for the starter to cool before repeating start procedure. 4. After engine start-up, check that the oil pressure warning light...

  • Page 208

    Starting procedure — engine manifold air temperature below 0°f (-18°c) in extremely cold weather below 0°f (-18°c) it may be beneficial to cycle the manifold heaters twice before attempting to start the engine. This can be accomplished by turning the ignition off for at least five seconds and then b...

  • Page 209

    Note: • engine idle speed will automatically increase to 1,000 rpm and engage the variable geometry turbo- charger at low coolant temperatures to improve engine warm-up. • when a diesel engine is allowed to run out of fuel or the fuel gels at low temperatures, air is pulled into the fuel system. If ...

  • Page 210

    Warning! • do not leave children or animals inside parked vehicles in hot weather. Interior heat build up may cause serious injury or death. • when leaving the vehicle, always make sure the keyless ignition node is in the “off” mode, re- move the key fob from the vehicle and lock the vehicle. • neve...

  • Page 211

    The post-heat cycle of the intake manifold heater system. The number of cycles and the length of the cycling operation is controlled by the engine control module. Post-heat operation can run for several minutes, and then the electrical system and voltmeter needle will stabilize. The cycling action w...

  • Page 212

    • climatized ultra low sulfur diesel fuel is a blend of number 2 ultra low sulfur and number 1 ultra low sulfur diesel fuels which reduces the temperature at which wax crystals form in fuel. • the fuel grade should be clearly marked on the pump at the fuel station. • the engine requires the use of “...

  • Page 213

    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 ca...

  • Page 214

    • operating the exhaust brake at idle will greatly im- prove warm up rate and will help keep the engine close to operating temperature during extended idle. Engine idling avoid prolonged idling, long periods of idling may be harmful to your engine because combustion chamber temperatures can drop so ...

  • Page 215

    2. The engine rpm will go up to 1100 rpm. To increase the rpm, push and hold the accel/resume switch and the idle speed will increase to approximately 1500 rpm. To decrease the rpm, push and hold the decel switch and the idle speed will decrease to approxi- mately 1100 rpm. 3. To cancel the idle–up ...

  • Page 216

    Driving condition load turbo- charger tempera- ture idle time (min.) before en- gine shutdown stop and go empty cool less than one stop and go medium one highway speeds medium warm two city traffic maximum gcwr three highway speeds maximum gcwr four uphill grade maximum gcwr hot five idle shutdown t...

  • Page 217

    Operating precautions avoid overheating the engine the temperature of the engine coolant (antifreeze) (a mixture of 50% ethylene-glycol and 50% water) must not exceed the normal range of the temperature gauge 240°f (116°c) with a 21 psi (145 kpa) coolant pressure cap. Usually the engine coolant (ant...

  • Page 218

    Do not operate the engine with low oil pressure when the engine is at normal operating temperature, the minimum oil pressures required are: idle 700 to 800 rpm 10 psi (69 kpa) full speed and load 30 psi (207 kpa) caution! If oil pressure falls to less than normal readings, shut the engine off immedi...

  • Page 219

    Engine block heater — if equipped the engine block heater warms engine coolant and permits quicker starts in cold weather. Connect the heater cord to a ground-fault interrupter protected 110–115 volt ac electrical outlet with a grounded, three-wire exten- sion cord. The engine block heater cord is r...

  • Page 220

    Diesel exhaust brake (engine braking) the purpose of the exhaust brake (engine braking) fea- ture is to supply negative (braking) torque from 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 e...

  • Page 221

    Removes pressure from the accelerator pedal. Exhaust braking is most effective when the engine rpm is higher. The automatic transmission will downshift more aggres- sively in tow/haul mode when the exhaust brake is enabled to increase brake performance. Caution! Use of aftermarket exhaust brakes is ...

  • Page 222

    Automatic exhaust brake can be enabled by pushing the exhaust brake button again anytime after the normal full exhaust brake has been turned on. The “exhaust brake indicator” in the evic/did will change from yellow to green when automatic exhaust brake is enabled. Push- ing the exhaust brake button ...

  • Page 223

    Warning! (continued) • unintended movement of a vehicle could injure those in or 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, turn the engine off, and r...

  • Page 224

    Key ignition park interlock this vehicle is equipped with a key ignition park inter- lock which requires the transmission to be in park before the ignition switch can be turned to the lock/ off (key removal) position. The key fob can only be removed from the ignition when the ignition is in the lock...

  • Page 225

    Self-calibrating; therefore, the first few shifts on a new vehicle may be somewhat abrupt. This is a normal condition, and precision shifts will develop within a few hundred miles (kilometers). Only shift from drive to park or reverse when the accelerator pedal is released and the vehicle is stopped...

  • Page 226

    When parking on a level surface, you may shift the transmission into park first, and then apply the parking brake. When parking on a hill, apply the parking brake before shifting the transmission to park, otherwise the load on the transmission locking mechanism may make it diffi- cult to move the sh...

  • Page 227

    Warning! (continued) • it is dangerous to shift out of park or neutral if the engine speed is higher than idle speed. If your foot is not firmly pressing the brake pedal, the vehicle could accelerate quickly forward or in re- verse. You could lose control of the vehicle and hit someone or something....

  • Page 228

    Warning! (continued) • never leave children alone in a vehicle, or with access to an unlocked vehicle. Allowing children to be in a vehicle unattended is dangerous for a number of reasons. A child or others could be seriously or fatally injured. Children should be warned not to touch the parking bra...

  • Page 229

    • release the shift lever and make sure it is fully seated in the park gate. • look at the transmission gear position display and verify that it indicates the park position (p). • with brake pedal released, verify that the shift lever will not move out of park. Reverse (r) this range is for moving t...

  • Page 230

    Drive (d) 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. Th...

  • Page 231

    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 ...

  • Page 232

    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 off position. 4. Wait approximately 10 seconds. 5. Restart the engine. 6. Shi...

  • Page 233

    To exit ers mode, simply push and hold the ers (+) switch until the gear limit display disappears from the instrument cluster. 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 a collision or pers...

  • Page 234

    Caution! When using ers for engine braking while descend- ing steep grades, be careful not to overspeed the engine. Apply the brakes as needed to prevent en- gine overspeed. Overdrive operation the automatic transmission includes an electronically controlled overdrive (fifth and sixth gears). The tr...

  • Page 235

    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. Normal operation is always the default at engine start-up. If tow/haul mode is desired, the switch must be pressed ...

  • Page 236

    Note: • the torque converter clutch will not engage (and 68rfe-equipped trucks will not shift to sixth gear), until the transmission fluid and engine coolant are warm [usually after 1 to 3 miles (2 to 5 km) of driving]. Because the engine speed is higher when the torque converter clutch is not engag...

  • Page 237

    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. Fully press the clutch pedal before shifting gears. As you release the clutch pedal, lightly press the accelerator pedal. This transmis...

  • Page 238

    Recommended vehicle shift speeds to utilize your manual transmission efficiently for both fuel economy and performance, it should be upshifted as listed in recommended shift speed chart. Shift at the vehicle speeds listed for acceleration. When heavily loaded or pulling a trailer these recommended u...

  • Page 239

    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 downshiftin...

  • Page 240

    Caution! If you skip a gear while downshifting or downshift at too high of a vehicle speed, these conditions may cause the engine to overspeed if too low of a gear is selected and the clutch pedal is released. Damage to the clutch and the transmission can result from skipping a gear while downshifti...

  • Page 241

    Switch. Connections to the switches are found under the hood in the connectors attached to the auxiliary power distribution center. You have the ability to configure the functionality of the auxiliary switches via the electronic vehicle information center (evic) or driver information display (did). ...

  • Page 242

    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 to operate the pto in this mode the vehicle must meet the following conditions: • be in park position (vehicles equipped with auto- mat...

  • Page 243

    Be used respectively. To disengage pto operation and return to “standard vehicle operation” simply toggle the pto switch to the off position. The torque converter clutch (tcc) will automatically engage at engine speeds above 1,200 rpm (engine speed) in pto stationary mode. Once engaged, the tcc will...

  • Page 244

    • 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 provided circuits. The customer may choose to use the pto while the vehicle is moving. To do so, the pto function must be acti...

  • Page 245

    Warning! In case of engine runaway due to flammable fumes from fuel spills or turbocharger oil leaks being sucked into the engine, do the following to help avoid personal injury and/or vehicle damage: 1. Turn the ignition switch to the off position. 2. Using a co2 or dry chemical type fire extinguis...

  • Page 246

    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 sepa...

  • Page 247

    Note: • if you accidentally fill the fuel tank with gasoline on your diesel vehicle, do not start the vehicle. If you restart your vehicle you risk damaging the engine and fuel system. Please call your local dealer for service. • a maximum blend of 5% biodiesel meeting astm specification d-975 may b...

  • Page 248

    Comply with the requirements outlined below. It is im- portant that you understand and comply with these requirements. Failure to comply with oil change require- ments for vehicles operating on biodiesel blends up to b20 will result in premature engine wear. Such wear is not covered by the new vehic...

  • Page 249

    Fuel water separation — must use mopar/ cummins approved fuel filter elements you must use mopar/cummins approved fuel filter elements in both your engine mounted filter and frame mounted filter. Biodiesel fuel has a natural affinity to water and water accelerates microbial growth. Your mopar/cummin...

  • Page 250

    Caution! • under no circumstances should oil change inter- vals exceed 15,000 miles (24 000 km) pickup or 12,500 miles (20 000 km) chassis cab if operation occurs with greater than 5% biodiesel blends. Oil change intervals should not exceed 6 months in either case. Failure to comply with these oil c...

  • Page 251

    Note: there is no fuel filler cap. A flapper door inside the filler pipe seals the system. 2. Insert the fuel nozzle fully into the filler pipe – the nozzle opens and holds the flapper door while refuel- ing. 3. Fill the vehicle with fuel – when the fuel nozzle “clicks” or shuts off the fuel tank is...

  • Page 252

    2. Insert funnel into same filler pipe opening as the fuel nozzle. Note: ensure funnel is inserted fully to hold flapper door open. 3. Pour fuel into funnel opening. 4. Remove funnel from filler pipe, clean off prior to putting back in the jack kit. Fuel fill funnel location 2500/3500 models emergen...

  • Page 253

    Caution! To avoid fuel spillage and overfilling, do not “top off” the fuel tank after filling. Warning! • never have any smoking materials lit in or near the vehicle when the fuel door is open or the tank is being filled. • never add fuel when the engine is running. This is in violation of most stat...

  • Page 254

    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! ...

  • Page 255

    Microbes form “slime” that will clog the fuel filtration system 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 “mai...

  • Page 256

    Adding diesel exhaust fluid the def gauge (located on the instrument cluster) will display the level of def remaining in the tank. Refer to “instrument cluster” and “instrument cluster descrip- tions” in “understanding your instrument panel” for further information. Note: driving conditions (altitud...

  • Page 257

    1 — diesel exhaust fluid fill location 2 — diesel fuel fill location 2. Insert def fill adapter/nozzle into def tank filler neck. Caution! • to avoid def spillage, and possible damage to the def tank from overfilling, do not “top off” the def tank after filling. (continued) def filler cap and fuel f...

  • Page 258

    Caution! (continued) • do not overfill. Def will freeze below 12ºf (-11ºc). The def system is designed to work in temperatures below the def freezing point, how- ever, if the tank is overfilled and freezes, the system could be damaged. • when def is spilled, clean the area immediately with water and...

  • Page 259

    4. Reinstall cap onto def tank. Filling the def tank in cold climates since def will begin to freeze at 12°f (-11°c), your vehicle is equipped with an automatic def heating system. This allows the def injection system to operate properly at temperatures below 12°f (-11°c). If your vehicle is not in ...

  • Page 260

    Diesel exhaust fluid your vehicle is equipped with a selective catalytic re- duction system to meet the very stringent diesel emis- sions standards required by the environmental protec- tion agency. The purpose of the scr system is to reduce levels of nox (oxides of nitrogen emitted from engines) th...

  • Page 261

    • uqs sensor 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) or ⬙driver information display (did)” in “understa...

  • Page 263: Contents

    What to do in emergencies contents 䡵 jump starting . . . . . . . . . . . . . . . . . . . . . .262 ▫ with portable starting unit. . . . . . . . . . . . . . .265 6.

  • Page 264

    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 connecting jumper cables or allow cable clamps to touch each other. Keep open flames or sparks away from battery vent holes. Always ...

  • Page 265

    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. Note: do not jump off fuses. Only jump directly off positive post. Warning! Do not permit vehicles to touch each other as this could establis...

  • Page 266

    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...

  • Page 267

    Warning! Any procedure other than above could result in: • personal injury caused by electrolyte squirting out the battery vent. • personal injury or property damage due to battery explosion. • damage to charging system of booster vehicle or of immobilized vehicle. With portable starting unit there ...

  • Page 269: Maintaining Your Vehicle

    Maintaining your vehicle contents 䡵 engine compartment — 6.7l diesel — six-speed 68rfe (2500/3500 models) . . . . . . .269 䡵 engine compartment — 6.7l diesel — six-speed as69rc hd (3500/chassis cab models) . . . . . . . . . . . . . . . . . . . . . . . . . . . .270 䡵 maintenance procedures . . . . . ...

  • Page 270

    ▫ manual transmission — if equipped. . . . . . . .298 ▫ automatic transmission — if equipped. . . . . .299 ▫ noise control system required maintenance & warranty . . . . . . . . . . . . . . . . . . . . . . . . . . .303 䡵 fluid capacities . . . . . . . . . . . . . . . . . . . .308 䡵 fluids, lubricant...

  • Page 271

    Engine compartment — 6.7l diesel — six-speed 68rfe (2500/3500 models) 1 — battery 7 — washer fluid reservoir 2 — engine coolant reservoir 8 — power steering fluid reservoir 3 — automatic transmission dipstick 9 — power distribution center 4 — brake fluid reservoir 10 — engine oil dipstick 5 — batter...

  • Page 272

    Engine compartment — 6.7l diesel — six-speed as69rc hd (3500/chassis cab models) 1 — battery 7 — washer fluid reservoir 2 — engine coolant reservoir 8 — power steering fluid reservoir 3 — automatic transmission dipstick 9 — power distribution center 4 — brake fluid reservoir 10 — engine oil dipstick...

  • Page 273

    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 futu...

  • Page 274

    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. Checking the oil while the vehicle is on level ground will improve the accuracy of the oil level readings. Add ...

  • Page 275

    Only when the level on the dipstick is below the “add” mark. The total capacity from the add mark to the full 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 lev...

  • Page 276

    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 n...

  • Page 277

    Caution! Failure to use sae 5w-40 synthetic engine oil in ambient temperatures below 0°f (-18°c) could result in severe engine damage. Engine oil not designated by the fca or cummins material standards and api cj-4 should not be used, as engine and exhaust system durability may be compro- mised. The...

  • Page 278

    The engine oil. Engine oil is an engineered product and its performance may be impaired by supplemental addi- tives. 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 c...

  • Page 279

    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) or driver information display (did) when service is required. Refer to “electronic vehicle information center (evic)”...

  • Page 280

    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 to this sensor could result in major engine and/or exhaust aftertreatment damage. We recommend you use mopar brand parts. Even though y...

  • Page 281

    2. Lift the air cleaner cover to access the air cleaner filter. Air cleaner filter cover 1 — clean air hose clamp 2 — air cleaner filter cover 3 — screws open air cleaner filter assembly 1 — air cleaner cover 2 — air cleaner filter 7 maintaining your vehicle 279.

  • Page 282

    3. Remove the air cleaner filter element from the housing assembly. Engine air cleaner filter installation note: inspect and clean the housing if dirt or debris is present before replacing the air filter element. 1. Install the air cleaner filter element into the housing assembly with the air cleane...

  • Page 283

    Second filter location is on the frame behind the front axle. The best access to this water drain valve is from under the vehicle. Caution! • do not drain the fuel/water separator filters when the engine is running. • diesel fuel will damage blacktop paving surfaces. Drain the filters into an approp...

  • Page 284

    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 ...

  • Page 285

    Caution! • diesel fuel will damage blacktop paving surfaces. Drain the filter into an appropriate container. • 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...

  • Page 286

    5. Remove lid using a socket or strap wrench. Rotate counterclockwise for removal. Remove used o-ring and discard 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-r...

  • Page 287

    Caution! • diesel fuel will damage blacktop paving surfaces. Drain the filter into an appropriate container. • 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...

  • Page 288

    5. Remove lid using a socket or strap wrench. Rotate counterclockwise for removal. Remove used o-ring and discard 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-r...

  • Page 289

    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 unde...

  • Page 290

    • use of biodiesel mixture in excess of 20% can nega- tively 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 use with your cummins diesel engine. • in addition, commerci...

  • Page 291

    Warning! (continued) 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. Diesel exhaust fluid diesel exhaust fluid (def) sometimes known simply by the name of its active component, ur...

  • Page 292

    Caution! (continued) 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 “fas...

  • Page 293

    Flushed and refilled with fresh coolant. Check the front of the a/c condenser (if equipped) or radiator for any accumulation of bugs, leaves, etc. If dirty, clean by gently spraying water from a garden hose vertically down the face of the a/c condenser (if equipped) or the back of the radiator core....

  • Page 294

    Caution! • mixing of engine coolant (antifreeze) other than specified organic additive technology (oat) en- gine coolant (antifreeze), may result in engine damage and may decrease corrosion protection. Organic additive technology (oat) engine cool- ant is different and should not be mixed with hybri...

  • Page 295

    Important that you use the same engine coolant (oat coolant conforming to ms.90032) throughout the life of your vehicle. Please review these recommendations for using organic additive technology (oat) engine coolant (antifreeze) that meets the requirements of fca material standard ms.90032. When add...

  • Page 296

    • mixing engine coolant (antifreeze) types is not recom- mended and can result in cooling system damage. If hoat and oat coolant are mixed in an emergency, have a authorized dealer drain, flush, and refill with oat coolant (conforming to ms.90032) as soon as possible. Cooling system pressure cap the...

  • Page 297

    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. Points to remember note: when the vehicle is stopped after a few miles/ kilometers of operation...

  • Page 298

    • 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 engine coolant (antifreeze) performance, poor gas mileage, and increased emis- sions. Charge air cooler — inter-cooler...

  • Page 299

    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. Warn...

  • Page 300

    Warning! (continued) • do not allow petroleum based fluid to contaminate 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 t...

  • Page 301

    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. Automatic transmission — if equipped selection of lubricant it is important to use the proper transmission fluid to ensure optimum transmission performance and life. ...

  • Page 302

    Of special dyes for diagnosing fluid leaks. Avoid using transmission sealers as they may adversely affect seals. Caution! Do not use chemical flushes in your transmission as the chemicals can damage your transmission compo- nents. Such damage is not covered by the new vehicle limited warranty. Fluid...

  • Page 303

    5. Place the shift lever momentarily into each gear posi- tion (allowing time for the transmission to fully en- gage in each position), ending with the transmission in park. 6. Remove the dipstick, wipe it clean and reinsert it until seated. 7. Remove the dipstick again and note the fluid level on b...

  • Page 304

    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 60-70°f / 16-21°c for 68rfe transmis- sion, or 68-86°f / 20-30°c for as69rc transmission. Only use the cold region of t...

  • Page 305

    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 ...

  • Page 306

    Or suspected. Proper maintenance of the entire vehicle will help the effectiveness of the noise control systems. 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, bur...

  • Page 307

    • removal of the air ducting. Exhaust system • removal or rendering inoperative exhaust system components including the muffler or tailpipe. Engine cooling system • removal or rendering inoperative the fan clutch. • removal of the fan shroud. Noise emission warranty the manufacturer warrants that th...

  • Page 308

    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 7,500 15,000 22,500 30,000 37,500 45,000 52,500 60,000 kilometers 12 000 24 000 36 000 48 000...

  • Page 309

    Noise systems maintenance chart and service log — insert month, day, year under column mileage closest to the mileage at which service was performed. 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 sy...

  • Page 310

    Fluid capacities u.S. Metric fuel (approximate) 2500/3500 standard cab longbed models 28 gallons 106 liters 2500/3500 crew/mega cab shortbed models 31 gallons 129 liters 2500/3500 crew cab longbed models 32 gallons 132 liters standard rear tank – chassis cab only 52 gallons 197 liters optional midsh...

  • Page 311

    Fluids, lubricants and genuine parts engine component fluid, lubricant, or genuine part engine coolant we recommend you use mopar antifreeze/coolant 10 year/150,000 mile formula oat (organic additive technology). Engine oil in ambient temperatures above 0°f (-18°c), we recommend you use 15w-40 engin...

  • Page 312

    Component fluid, lubricant, or genuine part crankcase ventilation filter we recommend you use mopar ccv filter. Fuel selection 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 pp...

  • Page 313

    Component fluid, lubricant, or genuine part diesel exhaust fluid mopar 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 assistance in locating def ...

  • Page 314

    Component fluid, lubricant, or genuine part front and rear axle fluid (2500/3500) we recommend you use synthetic, gl-5 sae 75w-85. Limited slip additive is not required for limited-slip rear axles. Front and rear axle fluid (4500/5500) we recommend you use synthetic, gl-5 sae 75w-90. Limited slip ad...

  • Page 315: Maintenance Schedule

    Maintenance schedule contents 䡵 maintenance schedule — diesel engine . . . . . . . . . . . . . . . . . . . . . . .314 ▫ oil change indicator system — cummins diesel . . . . . . . . . . . . . . . . . . . . . .314 ▫ perform service indicator — cummins diesel . . .316 ▫ maintenance chart — cummins dies...

  • Page 316

    Maintenance schedule — diesel engine 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 grou...

  • Page 317

    “oil change due” on your electronic vehicle informa- tion center (evic) or driver information display (did). The oil change reminder will remind the owner to change the engine oil every 15,000 miles or 500 hours, whichever comes first, except for the chassis cab models and pickup models configured w...

  • Page 318

    Information regarding operation of chassis cab models and pickup models configured for use with biodiesel blend (b6-b20) fuel meeting astm specification d-7467. Perform service indicator — cummins diesel your vehicle will require emissions maintenance at a set interval. To help remind you when this ...

  • Page 319

    Maintenance chart — cummins diesel engine mileage or time passed (whichever comes first): 7,500 15,000 22,500 30,000 37,500 45,000 52,500 60,000 67,500 75,000 82,500 90,000 97,500 105,000 1 12,500 120,000 127,500 135,000 142,500 150,000 or months: 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102 1...

  • Page 320

    Mileage or time passed (whichever comes first): 7,500 15,000 22,500 30,000 37,500 45,000 52,500 60,000 67,500 75,000 82,500 90,000 97,500 105,000 1 12,500 120,000 127,500 135,000 142,500 150,000 or months: 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120 or kilometers: 12,000 24,000 36...

  • Page 321

    Mileage or time passed (whichever comes first): 7,500 15,000 22,500 30,000 37,500 45,000 52,500 60,000 67,500 75,000 82,500 90,000 97,500 105,000 1 12,500 120,000 127,500 135,000 142,500 150,000 or months: 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120 or kilometers: 12,000 24,000 36...

  • Page 322

    Mileage or time passed (whichever comes first): 7,500 15,000 22,500 30,000 37,500 45,000 52,500 60,000 67,500 75,000 82,500 90,000 97,500 105,000 1 12,500 120,000 127,500 135,000 142,500 150,000 or months: 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120 or kilometers: 12,000 24,000 36...

  • Page 323

    Mileage or time passed (whichever comes first): 7,500 15,000 22,500 30,000 37,500 45,000 52,500 60,000 67,500 75,000 82,500 90,000 97,500 105,000 1 12,500 120,000 127,500 135,000 142,500 150,000 or months: 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120 or kilometers: 12,000 24,000 36...

  • Page 324

    Mileage or time passed (whichever comes first): 7,500 15,000 22,500 30,000 37,500 45,000 52,500 60,000 67,500 75,000 82,500 90,000 97,500 105,000 1 12,500 120,000 127,500 135,000 142,500 150,000 or months: 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120 or kilometers: 12,000 24,000 36...

  • Page 325

    **** under no circumstances should the air cleaner filter element exceed 30,000 miles (48,000 km) or 24 months, whichever comes first. Caution! ***the manufacturer highly recommends that all cooling system service, maintenance, and repairs be performed by your local authorized dealer. Warning! • you...

  • Page 327: Index

    Index 8.

  • Page 328

    Adding engine coolant (antifreeze) . . . . . . . . . . . .106 adding fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80 air cleaner, engine (engine air cleaner filter) . . . . .94 antifreeze (engine coolant) . . . . . . . . . . . . . . . . . .105 capacities . . . . . . . . . . . . . ....

  • Page 329

    Diesel fuel system, re-priming . . . . . . . . . . . . . . .101 disposal antifreeze (engine coolant) . . . . . . . . . . . . . . . .108 draining fuel/water separator filter . . . . . . . . . . . .97 electronic vehicle information center (evic) . . . . . .25 engine. . . . . . . . . . . . . . . . . . ...

  • Page 330

    Information center, vehicle . . . . . . . . . . . . . . . . . . .25 instrument cluster . . . . . . . . . . . . . . . . . . . . . . . . .16 intervention regeneration strategy . . . . . . . . . . . . . .32 keyless enter-n-go . . . . . . . . . . . . . . . . . . . . . . . .65 maintenance procedures . . ...

  • Page 331

    Tip start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64 transfer case fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118 transmission viscosity, engine oil . . . . . . . . . . . . . . . . . . . . . . . .93 voltmeter. . . . . . . . . . . . . . . . . . . . . ....

  • Page 332

    Adding engine coolant (antifreeze) . . . . . . . . . . . .292 adding fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . .248 air cleaner, engine (engine air cleaner filter) . . . .276 air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .276 antifreeze (engine coolant) . ...

  • Page 333

    Radiator cap . . . . . . . . . . . . . . . . . . . . . . . . . .294 selection of coolant (antifreeze) . . . . . . . .291 , 309 diesel exhaust brake . . . . . . . . . . . . . . . . . . . . . . .218 diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .243 diesel fuel requirements. . ...

  • Page 334

    Fluid level checks brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .296 manual transmission . . . . . . . . . . . . . . . . . . . .298 transfer case . . . . . . . . . . . . . . . . . . . . . . . . . .298 fluids, lubricants and genuine parts . . . . . . . . . . .309 fuel . . . . ....

  • Page 335

    Noise emission warranty. . . . . . . . . . . . . . . . . . . .303 oil change indicator . . . . . . . . . . . . . . . . . . . . . . .314 oil, engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .271 capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . .308 change interval . ....

  • Page 336

    Engine block heater . . . . . . . . . . . . . . . . .202 , 217 manual transmission . . . . . . . . . . . . . . . . . . . .196 remote . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138 starting procedures . . . . . . . . . . . . . . . . . . . . . . . .196 starting procedures (diesel engin...

  • Page 337

    Installation of radio transmitting equipment special design considerations are incorporated into this vehicle’s electronic system to provide immunity to radio frequency signals. Mobile two-way radios and telephone equipment must be installed properly by trained person- nel. The following must be obs...

  • Page 338

    First edition printed in u.S.A. ©2015 fca us llc. All rights reserved. Ram is a registered trademark of fca us llc. 16d241-226-aa stick with the specialists ®.