Dodge 2009 Ram Diesel manual

148920 Ram Diesel.indd 1 148920 Ram Diesel.indd 1 9/29/08 10:48:44 AM 9/29/08 10:48:44 AM[...]

VEHICLES SOLD IN CANADA W ith respect to any V ehicles Sold in Canada, the name Chrysler LLC shall be deemed to be deleted and the name Chrysler Canada Inc. used in substitution therefor . DRIVING AND ALCOHOL Drunken driving is one of the most fr equent causes of accidents. Y our driving ability can be seriously impaired with blood alcohol levels f[...]

T ABLE OF CONTENTS SECTION P AGE 1 INTRODUCTION .............................................................3 2 THINGS TO KNOW BEFORE ST AR TING YOUR VEHICLE ............................... 5 3 UNDERST ANDING THE FEA TURES OF YOUR VEHICLE ................................ 9 4 UNDERST ANDING YOUR INSTRUMENT P ANEL ...................................[...]

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INTRODUCTION CONTENTS 䡵 A Message From Chrysler LLC ............. 4 1[...]

A MESSAGE FROM CHRYSLER LLC Chrysler LLC and Cummins 威 welcome you as a Cum- mins 威 turbocharged diesel-power ed truck owner . Almost 100% of all heavy duty trucks ar e diesel-powered because of the fuel economy , rugged durability , and high torque which permits pulling heavy loads. Cummins 威 , engines power well over half of these trucks. N[...]

THINGS T O KNOW BEFORE ST ARTING YOUR VEHICLE CONTENTS 䡵 Steering Wheel Lock — If Equipped ......... 6 ▫ T o Manually Lock The Steering Wheel ...... 6 ▫ T o Release The Steering Wheel Lock ........ 6 䡵 Engine Break-In Recommendations .......... 6 2[...]

STEERING WHEEL LOCK — IF EQUIPPED Y our vehicle may be equipped with a passive steering wheel lock. This lock prevents steering the vehicle with- out the ignition key . If the steering wheel is moved approximately a half turn in either dir ection and the key is not in the ignition switch, the steering wheel will lock. T o Manually Lock the Steeri[...]

For additional vehicle break-in r equirements, refer to “T railer T owing” in Section 5 of the Owners Manual. • W arm up the engine before placing it under load. • Do not operate the engine at idle for prolonged periods. • Use the appropriate transmission gear to pr event engine lugging. • Observe vehicle oil pressur e and temperature i[...]

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UNDERST ANDING THE FEA TURES OF YOUR VEHICLE CONTENTS 䡵 Overhead Console W ith Electronic V ehicle Information Center (EVIC) ................. 1 0 ▫ Dome/Reading Lights ................ 1 0 ▫ Electronic V ehicle Information Center (EVIC) — If Equipped ....................... 1 1 ▫ Compass/T emperature Button ........... 1 8 3[...]

OVERHEAD CONSOLE WITH ELECTRONIC VEHICLE INFORMA TION CENTER (EVIC) The overhead console contains dome/r eading lights, and an Electronic V ehicle Information Center (EVIC). Dome/Reading Lights Located in the overhead console ar e two dome/reading lights. The dome/reading lights illuminate when a door is opened or when the interior lights are turne[...]

Electronic V ehicle Information Center (EVIC) — If Equipped Pressing the MENU button will change the display to one of the following features: T rip Functions Pressing the STEP button allows you to scroll thr ough one of the following T rip Function features: • TRIP – Shows the total distance traveled since the last reset. T o reset the TRIP [...]

• A VG. MPG – Shows the average fuel economy since the last reset. When the fuel economy is r eset, the display will show dashes for two seconds. Then the history information will be erased, and the averaging will continue from the last fuel average r eading before the reset. (Example: If your EVIC displays 18 A VG. MPG and the RESET button is [...]

• PERSONAL SETTINGS NOT A V AILABLE – V ehicle not in P ARK or V ehicle in Motion (Manual T ransmis- sion Only) • LEFT/RIGHT FRONT DOOR AJAR (one or mor e, with a single chime if speed is above 1 mph (1.6 km/h) • LEFT/RIGHT REAR DOOR AJAR (one or more, with a single chime if speed is above 1 mph (1.6 km/h) • DOOR(S) AJAR (with a single ch[...]

scheduled oil change interval. The engine oil change indicator system is duty cycle based, which means the engine oil change interval may fluctuate, dependent upon your personal driving style. NOTE: When prompted by the Engine Oil Change Indicator System, the engine oil and filter must be changed. If not prompted by the Engine Oil Change Indicator [...]

Cooler , and cleaning of the EGR V alve. The procedure for clearing and resetting the “Perform Service” indicator message is located in the appropriate service informa- tion. Refer to the “Maintenance Schedule” in Section 8 for the proper emission maintenance intervals. Personal Settings (Customer Programmable Features) Personal settings al[...]

• “RKE UNLOCK DR V DR 1st” – When DR V DR 1st is selected, only the driver’s door will unlock on the first press of the r emote keyless entry UNLOCK button. When Driver Door 1st Press is selected, you must press the r emote keyless entry UNLOCK button twice to unlock the passenger’s doors. T o make your selec- tion, press and r elease t[...]

• “KEY OFF POWER DELA Y > OFF” – When this feature is selected, the power window switches, radio, hands–free system (if equipped), and power outlets will remain active for up to 10 minutes after the ignition switch is turned OFF . Opening a vehicle door will cancel this feature. T o make your selection, press and release the RESET butt[...]

Compass/T emperature Button Pressing the Compass/T emperature button will return the display to the normal compass/ temperature display . NOTE: T emperature accuracy can be af fected from heat soak. For best accuracy , the vehicle should be driven at a speed greater than 25 mph (40 km/h) for several min- utes. Automatic Compass Calibration This com[...]

Compass V ariance Compass V ariance is the differ ence between magnetic North and Geographic North. In some areas of the country , the difference between magnetic and geographic North is great enough to cause the compass to give false readings. If this occurs, the compass variance must be set using the following procedur e: NOTE: Magnetic materials[...]

1. T urn the ignition switch to the ON/RUN position. 2. Press the MENU button until “Personal Settings” is displayed. 3. Press the STEP button until “Compass V ariance” is displayed. 4. Press and r elease RESET button until the proper variance zone is selected according to the map. 5. Press and r elease the Compass button to exit. 20 UNDERS[...]

UNDERST ANDING YOUR INSTRUMENT P ANEL CONTENTS 䡵 Instrument Panel Featur es ................ 2 2 䡵 Instrument Cluster ..................... 2 3 ▫ 6.7L Diesel Engine .................... 2 3 䡵 Instrument Cluster Description ............. 2 4 4[...]

INSTRUMENT P ANEL FEA TURES 1 — Headlight Switch 6 — Passenger Airbag* 1 1 — TPMS “Light Load” Reset Switch* 16 — T ransfer Case Control Switch* 2 — Air Outlets 7 — Glove Box 12 — Power Sliding Back Glass Switch* 17 — Parking Brake Release Lever 3 — Instrument Cluster 8 — Passenger Airbag On/ Off Switch* 13 — Cupholders 18[...]

INSTRUMENT CLUSTER 6.7L Diesel Engine UNDERST ANDING YOUR INSTRUMENT P ANEL 23 4[...]

INSTRUMENT CLUSTER DESCRIPTION 1. Check Gages W arning Light This light will illuminate when the voltmeter , engine oil pressur e, or engine coolant temperature gauge indicates a reading either too high or too low . Examine the gauges carefully , and follow the instructions contained below for each indicated problem. NOTE: When the ignition switch [...]

3. T urn Signal Indicator Light The arrows will flash with the exterior turn signals when the turn signal lever is operated. 4. T achometer The tachometer indicates engine speed in revolutions per minute. CAUTION! Do not operate the engine with the tachometer pointer at high RPM for extended periods. Engine damage may occur . 5. Airbag W arning Lig[...]

9. Oil Pressur e Gauge The pointer should always indicate some oil pres- sure when the engine is r unning. A continuous high or low reading, under normal driving conditions, may indicate a lubrication system malfunction. Immedi- ate service should be obtained. NOTE: If the gauge pointer moves to either extreme of the gauge, the “Check Gages W arn[...]

CAUTION! Do not leave your vehicle unattended with the en- gine running, as you would not be able to react to the temperature indicator if the engine overheats. NOTE: • Engine idle speed will automatically increase to 1,000 RPM at elevated coolant temperatures to impr ove engine cooling. • If the gauge pointer moves to either extreme of the gau[...]

The two trip odometers show individual trip mileage. T o switch from odometer to trip odometers, pr ess and release the T rip Odometer button. T o reset a trip odometer , display the desired trip odom- eter to be reset then push and hold the button (appr oxi- mately two seconds) until the display resets. V ehicle W arning Messages When the appropri[...]

17. Malfunction Indicator Light (MIL) The Malfunction Indicator Light (MIL) is part of an onboard diagnostic system which monitors the emissions and engine control system. If the vehicle is ready for emissions testing the light will come on when the ignition is first turned on and remain on, as a bulb check, until the engine is started. If the vehi[...]

hydraulic system malfunction or a problem with the Brake Booster has been detected by the Anti-Lock Brake System (ABS) / Electronic Stability Pr ogram (ESP) sys- tem. In this case, the light will remain on until the condition has been corrected. If the pr oblem is related to the brake booster , the ABS pump will r un when applying the brake and a b[...]

“Brake W arning Light” will turn on along with the “ABS W arning Light.” Immediate repair to the ABS system is requir ed. Operation of the “Brake W arning Light” can be checked by turning the ignition switch from the OFF position to the ON position. The light should illuminate for approxi- mately two seconds. The light should then turn [...]

20. Cargo Light The cargo light will illuminate when the car go lamp is activated by pressing the car go light button on the headlight switch. 21. Electronic Thr ottle Control (ETC) W arning Light This light informs you of a problem with the Electronic Thr ottle Control (ETC) system. If a problem is detected, the light will come on while the engine[...]

24. T ire Pressur e Monitoring T elltale Light — If Equipped Each tire, including the spar e (if provided), should be checked monthly , when cold and inflated to the inflation pressur e recommended by the vehicle manufacturer on the vehicle placard or tir e inflation pressure label. (If your vehicle has tires of a dif ferent size than the size in[...]

Y our vehicle has also been equipped with a TPMS malfunction indicator to indicate when the system is not operating properly . The TPMS malfunction indicator is combined with the low tire pr essure telltale. When the system detects a malfunction, the telltale will flash for approximately one minute and then r emain continuously illuminated. This se[...]

T ire Light Load Inflation Switch – If Equipped The tire light load inflation switch allows you to choose between “Light Load” vehicle conditions and “Max Load” vehicle conditions, tire pr essures, and related TPMS warning levels. The switch is located on the instrument panel, below the climate contr ol panel. For additional information, [...]

28. Fuel Gauge Shows level of fuel in tank when ignition switch is in the ON position. 29. Low Fuel W arning Light This light will illuminate when the pointer is be- tween “E” and 1/8 indication mark (approximately 15% of tank volume) on the fuel gauge. When the fuel gauge pointer is on “E” (equivalent to Distance T o Empty [DTE ]=0o nt h e[...]

ST ARTING AND OPERA TING CONTENTS 䡵 Starting Procedur es ..................... 3 9 ▫ Manual T ransmission – If Equipped ........ 3 9 ▫ Automatic T ransmission – If Equipped ...... 3 9 ▫ Normal Starting Procedur e – Engine Manifold Air T emperature Above 66°F (19°C) ..................... 4 0 ▫ Starting Procedur e – Engine Manifol[...]

䡵 Engine Block Heater .................... 5 2 ▫ Block Heater Usage .................... 5 2 䡵 Diesel Exhaust Brake (Engine Braking) – If Equipped ........................... 5 3 䡵 Automatic T ransmission — If Equipped ....... 5 4 ▫ Automatic T ransmission W ith Overdrive (68RFE) — If Equipped (Ram T ruck Only) .... 5 4 ▫ Automati[...]

ST ARTING 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. W aiting a few minutes between such intervals will protect the starter fr om overheating. W ARNING! Do not leave children or animals inside pa[...]

• A 12–V olt heater built into the fuel filter housing aids in preventing fuel gelling. It is contr olled by a built-in thermostat. • A heated intake air system both improves engine starting and reduces the amount of white smoke generated by a warming engine. Normal Starting Procedure – Engine Manifold Air T emperature Above 66°F (19°C) O[...]

6. Check to see that there is oil pr essure. 7. Release the parking brake. Starting Procedure – Engine Manifold Air T emperature Below 66°F (19°C) NOTE: The temperature displayed on the over head console (if equipped) does not necessarily reflect the engine manifold air temperature. When engine tempera- tures fall below 66°F (19°C) the “W a[...]

3. After engine start-up, check to see that there is oil pressur e. 4. Allow the engine to idle about three minutes until the manifold heaters have completed the post-heat cycle. 5. Release the parking brake and drive. NOTE: • Engine idle speed will automatically increase to 1,000 RPM at low coolant temperatures to impr ove engine warm-up. • If[...]

NOTE: Excessive white smoke and poor engine perfor- mance will result if manifold heaters ar e not recycled. 2. Heat generated by the manifold heaters dissipates rapidly in a cold engine. If more than two minutes pass between the time the “W ait T o Start Light” turns off and the engine is started, recycle the manifold heaters by turning the ig[...]

Starting Fluids W ARNING! Starting fluids or flammable liquids are never to be used in the Cummins 威 diesel engine (see W arning label). Never pour diesel fuel, flammable liquid, starting fluids (ether) into the air cleaner canister , air intake piping, or turbocharger inlet in an attempt to start the vehicle. This could result in a flash fire an[...]

engine control module. Post-heat operation can r un for several minutes, and then the electrical system and voltmeter needle will stabilize. • The cycling action will cause temporary dimming of the headlamps, interior lamps, and also a noticeable reduction in blower motor speed. Cold Weather Precautions Operation in ambient temperature below 32°[...]

• The engine requir es the use of “Ultra Low Sulfur Diesel Fuel” . Use of incorrect fuel could r esult in engine and exhaust system damage. Refer to” Fuel Requirements” in Section 5. Engine Oil Usage Refer to “Maintenance Procedur es” in Section 7 of this manual for the correct engine oil viscosity . W inter Front Usage If a winter fr[...]

Y our vehicle is equipped with a turbo speed limiter , this feature limits the engine speed to 1,200 RPM when engine coolant temperatures ar e below 70°F (21°C). This feature is designed to pr otect the turbo charger from damage and will only operate in P ARK or NEUTRAL. If temperatures ar e below 32°F (0°C), operate the engine at moderate spee[...]

CAUTION! Extended periods of idle time may not allow the vehicle’s exhaust aftertreatment system to properly regenerate. This can lead to the illumination of the Malfunction Indicator Light (MIL) or an Electronic V ehicle Information Center (EVIC) warning message. Operating the engine for extended periods with the MIL illuminated or an EVIC warni[...]

NOTE: • During engine shut down on vehicles equipped with manual transmissions, it is normal for the diesel engine to resonate heavily for a moment during engine shut off. When the engine is connected to a manual transmission, this resonance causes load gear rattle from the transmission. This is commonly r eferred to as “shut down rattle.” Th[...]

Engine Speed Control CAUTION! Prevent overspeeding the engine going downhill. When descending steep grades, use a combination of gears and service brakes to control vehicle/engine speed. Overspeed can cause severe engine damage. Operating Precautions A void Overheating The Engine The temperature of the engine coolant (antifr eeze) (a mixture of 50%[...]

• Up Steep Hills — Select a lower transmission gear , but try and keep the torque converter clutch engaged. • Air Conditioning — T urn it off temporarily . Do Not Operate The Engine W ith Low Oil Pressure When the engine is at normal operating temperature, the minimum oil pressur es required ar e: Idle 700 to 800 RPM ............... 1 0 p s[...]

ENGINE BLOCK HEA TER The engine block heater warms engine coolant and permits quicker starts in cold weather . Connect the heater cord to a gr ound-fault interrupter protected 1 10–1 15 V olt AC electrical outlet with a grounded, thr ee-wire exten- sion cord. The engine block heater cord is r outed under the hood to the right side and can be loca[...]

DIESEL EXHAUST BRAKE (ENGINE BRAKING) – IF EQUIPPED The exhaust brake feature will only function when the driver turns the exhaust brake switch to the ON position. Once the switch is in the ON position and the vehicle is moving faster than 5 mph (8 km/h); the exhaust brake will automatically operate when the driver removes pressur e from the acce[...]

NOTE: For optimum braking power it is recommended to use the exhaust brake while in TOW/HAUL Mode. The purpose of the exhaust brake (engine braking) fea- ture is to supply negative (braking) tor que to the engine. T ypically , the engine braking is used for , but not limited to, vehicle towing applications where vehicle braking can be achieved by t[...]

Gear Ranges DO NOT race the engine when shifting from P ARK or NEUTRAL position into another gear range. P ARK This gear position supplements the parking brake by locking the transmission. The engine can be started in this range. Never use P ARK while the vehicle is in motion. Apply the parking brake when leaving the vehicle in this range. Always a[...]

W ARNING! (Continued) • It is dangerous to move the shift lever out of P ARK or NEUTRAL if the engine speed is higher than idle speed. If your foot is not firmly on the brake pedal, the vehicle could accelerate quickly forward or in reverse. Y ou could lose control of the vehicle and hit someone or something. Only shift into gear when the engine [...]

Overdrive Operation The overdrive automatic transmission contains an elec- tronically contr olled 5th and 6th (Overdrive). The trans- mission will automatically shift from DRIVE to Over - drive if the following conditions are pr esent: • the shift lever is in DRIVE; • the engine coolant has reached normal operating tem- perature; • vehicle sp[...]

When T o Use TOW HAUL When driving in hilly areas, towing a trailer , carrying a heavy load, etc., and frequent transmission shifting oc- curs, press the T OW/HAUL switch once to select T OW HAUL. In TOW HAUL mode, 4th to 5th gear upshifts are delayed. Shifts into 5th and 6th gear are still allowed under steady cruise conditions. Closed thr ottle d[...]

Switching from ERS to D-Mode can be done at any vehicle speed. T o switch from “Drive” mode to “ERS” mode, press the switch down (-) once. The curr ent gear will be maintained as the top gear . T o disable ERS, simply press and hold the switch up (+) until “D” is displayed in the instrument cluster odometer . W ARNING! Do not downshift [...]

when the transmission is sufficiently warm, will dem- onstrate that the transmission is able to shift into and out of Overdrive. • If the vehicle has not been driven in several days, the first few seconds of operation after shifting the trans- mission into gear may seem sluggish. This is due to the fluid partially draining from the tor que conver[...]

W ARNING! • Never use the P ARK position as a substitute for the parking brake. Always apply the parking brake fully when parked to guard against vehicle movement and possible injury or damage. • Y our vehicle could move and injure you and others if it is not completely in P ARK. Check by trying to move the shift lever back and forth without fi[...]

REVERSE Use this range only after the vehicle has come to a complete stop. NEUTRAL Shift into NEUTRAL when the vehicle is standing for prolonged periods with the engine r unning. The engine may be started in this range. Set the parking brake if you must leave the vehicle. DRIVE This position provides all forwar d gears, including 4th gear direct an[...]

Overdrive Operation The Overdrive automatic transmission contains an elec- tronically contr olled 5th and 6th (if equipped) speed (Overdrive). The transmission will automatically shift from DRIVE to Over drive if the following conditions are present: • the shift lever is in DRIVE; • the engine coolant has reached normal operating tem- perature;[...]

speeds above approximately 35 to 40 mph (57 to 65 km/h) for 6th to 5th and 22 to 25 mph (36 to 40 km/h) for 5th to 4th. When T o Use “TOW HAUL” and “O/D OFF” Modes When driving in hilly areas, towing a trailer , carrying a heavy load, etc., and frequent transmission shifting oc- curs, press the “T OW HAUL O/D OFF” switch once to select [...]

W ARNING! Do not use the T ow Haul feature when driving in icy or slippery conditions. The increased engine braking can cause the rear wheels to slide, and the vehicle to swing around with the possible loss of vehicle con- trol, which may cause an accident possibly resulting in personal injury or death. When T o Lock Out Overdrive When driving in h[...]

• If the vehicle has not been driven in several days, the first few seconds of operation after shifting the trans- mission into gear may seem sluggish. This is due to the fluid partially draining from the tor que converter into the transmission. This condition is normal and will not cause damage to the transmission. The torque con- verter will re[...]

Shifting T ruck models with manual transmission are equipped with a clutch interlocking ignition system. The clutch pedal must be fully depressed to start the vehicle. Fully depress the clutch pedal befor e shifting gears. As you release the clutch pedal, lightly depr ess the accelera- tor pedal. This transmission has a “creeper” 1st gear (L=lo[...]

Maximum Recommended Up-shift Speeds Gear Selec- tion L t o2 2t o3 3t o4 4t o5 5t o6 Maxi- mum Speed 7 mph (1 1 km/h) 15 mph (24 km/h) 25 mph (40 km/h) 40 mph (64 km/h) 45 mph (72 km/h) Downshifting Moving from a high gear down to a lower gear is recommended to pr eserve brakes when driving down steep hills. In addition, downshifting at the right ti[...]

Maximum Recommended Downshift Speeds CAUTION! Failure to follow the recommended downshifting speeds may cause the engine to overspeed and/or damage the clutch disc even if the clutch pedal is depressed. Maximum Recommended Downshifting Speeds Gear Selec- tion 6t o5 5t o4 4t o3 3t o2 2t oL Maxi- mum Speed 68 mph (109 km/h) 50 mph (80 km/h) 32 mph (5[...]

POWER T AKE OFF OPERA TION – IF EQUIPPED (CHASSIS CAB ONL Y) This vehicle when equipped with either the automatic six-speed or manual G-56 six-speed transmissions, will allow for an aftermarket upfit with a transmission driven PTO (power take of f). The customer will have the ability to operate the PTO in either a “stationary” or “mobile”[...]

disengage PTO operation and r eturn to “standard vehicle operation” simply turn the upfitter-pr ovided on/off switch to the OFF position or press the CANCEL cruise switch. T o operate the PTO via a r emote switch the customer must make sure the above conditions ar e met. It is vital for proper operation that the PT O and remote have been instal[...]

The customer may choose to use the PTO while the vehicle is moving. T o do so, the PTO function must be activated prior to taking the vehicle out of P ARK. This is accomplished by activating the upfitter-pr ovided PTO on/off switch. At this point, the customer may place the vehicle in a forward or r everse gear and have PTO operation. T o disengage[...]

No. 2 diesel fuel or dilute the No. 2 diesel fuel with 50% No. 1 diesel fuel. This will provide better pr otection from fuel gelling or wax-plugging of the fuel filters. W ARNING! 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[...]

ENGINE RUNA W A Y W ARNING! In case of engine runaway due to flammable fumes from gasoline spills or turbocharger oil leaks being sucked into the engine, do the following to help avoid personal injury and/or vehicle damage: 1. Shut off engine ignition switch. 2. Using a CO 2 or dry chemical type fire extin- guisher , direct the spray from the fire [...]

W ARNING! A fire may result if fuel is pumped into a portable container that is on a truck bed. Y ou could be burned. Always place fuel containers on the ground while filling. Fuel Filler Cap (Gas Cap) If the gas cap is lost or damaged, be sure the r eplacement cap is for use with this vehicle. CAUTION! Damage to the fuel system or emission control[...]

Bulk Fuel Storage If you store quantities of fuel, good maintenance of the stored fuel is also essential. Fuel contaminated with water will promote the gr owth of “microbes.” These microbes form “slime” that will clog fuel filters and lines. Drain condensation from the supply tank and change the line filter on a regular basis. NOTE: When a [...]

WHA T T O DO IN EMERGENCIES CONTENTS 䡵 Jump-Starting ........................ 7 8 ▫ W ith Portable Starting Unit ............. 8 1 6[...]

JUMP-ST ARTING W ARNING! • T o prevent personal injury or damage to clothing, do not allow battery fluid to contact eyes, skin or fabrics. Do not lean over a battery when connect- ing jumper cables or allow cable clamps to touch each other . Keep open flames or sparks away from battery vent holes. Always wear eye protection when working with batt[...]

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 . W ARNING! Do not permit vehicles to touch each other as this could establish a ground connection and personal injury could result. Attaching Booster Cables 1 — Discharged Battery 2 — Boo[...]

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 gr ease. W ARNING! • Do not connect the cable to the negative post of the discharge[...]

W ARNING! 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 ar e many types of these units available. F[...]

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MAINT AINING YOUR VEHICLE CONTENTS 䡵 Engine Compartment — 6.7L Diesel ......... 8 5 䡵 Maintenance Procedur es .................. 8 6 ▫ Engine Oil .......................... 8 6 ▫ Engine Air Cleaner Filter ................ 9 0 ▫ Draining Fuel/W ater Separator Filter ....... 9 2 ▫ Priming If The Engine Has Run Out Of Fuel ..............[...]

▫ Automatic T ransmission — If Equipped . . . 108 ▫ Noise Control System Requir ed Maintenance & W arranty ........................ 1 1 2 䡵 Fluid Capacities ..................... 1 1 6 䡵 Fluids, Lubricants And Genuine Parts ...... 1 1 7 ▫ Engine ........................... 1 1 7 ▫ Chassis .......................... 1 1 9 84 MAINT [...]

ENGINE COMP ARTMENT — 6.7L DIESEL 1 — Battery 8 — W asher Fluid Reservoir 2 — Engine Oil Fill 9 — Integrated Power Module 3 — Engine Oil Dipstick 10 — Engine Coolant Reservoir 4 — Automatic T ransmission Dipstick 1 1 — Power Steering Fluid Reservoir 5 — Brake Fluid Reservoir 12 — Coolant Pressur e Cap 6 — Clutch Master Cylin[...]

MAINTENANCE PROCEDURES The pages that follow contain the required maintenance services determined by the engineers who designed your vehicle. Besides the maintenance items for which there ar e fixed maintenance intervals, there ar e other items that should operate satisfactorily without periodic maintenance. However , if a malfunction of these item[...]

Checking the oil while the vehicle is on level ground will improve the accuracy of the oil level r eadings. Add oil only when the level on the dipstick is below the “ADD” mark. The total capacity from the low mark to the high mark is 2 qts (1.9L). CAUTION! Overfilling or underfilling the crankcase will cause oil aeration or loss of oil pressure[...]

Oils with a high ash content may produce deposits on valves that can progr ess to guttering and valve burning. 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 sp[...]

Engine oil not designated by the Chrysler or Cummins 威 Material Standards and API CJ-4 should not be used, as engine and exhaust system durability may be compro- mised. The engine oil filler cap also shows the recom- mended engine oil viscosity for your engine. For infor- mation on engine oil filler cap location, refer to “Engine Compartment”[...]

Engine Air Cleaner Filter CAUTION! All air entering the engine intake must be filtered. The abrasive particles in unfiltered air will cause rapid wear to engine components. The condition of the air cleaner filter is monitored by the Engine Control Module. The Electr onic V ehicle Informa- tion Center (EVIC) will display SER VICE AIR FIL TER when se[...]

If the vehicle experiences a sudden loss of engine power when being driven in heavy snow , rain or when plowing snow , and the EVIC message center states SER VICE AIR FIL TER is showing a plugged filter , then visually inspect the air filter for snow/ice build up or extreme water saturation. If the air filter is not damaged, remove all snow/ice and[...]

Draining Fuel/W ater Separator Filter The fuel filter and water separator assembly is located on the driver’s side of the engine. The best access to the water drain valve is through the driver’s side wheel well. CAUTION! • Do not drain the fuel/water separator filter when the engine is running. • Diesel fuel will damage blacktop paving surf[...]

If the “W ater In Fuel Indicator Light” comes on and a single chime is heard while you ar e driving, or with the key in the ON position, there may be a pr oblem with your water separator wiring or sensor . See your autho- rized dealer for service. Upon proper draining of the water fr om the fuel filter , the “W ater In Fuel Indicator Light”[...]

Fuel Filter Replacement NOTE: Using a fuel filter that does not meet the manufacturer’s filtration and water separating r equire- ments can severely impact fuel system life and r eliability . CAUTION! • Diesel fuel will damage blacktop paving surfaces. Drain the filter into an appropriate container . • Do not prefill the fuel filter when inst[...]

Priming If The Engine Has Run Out Of Fuel W ARNING! Do not open the high pressure fuel system with the engine running. Engine operation causes high fuel pressure. High pressure fuel spray can cause serious injury or death. 1. Add a substantial amount of fuel to the tank, approxi- mately 5 to 10 gal (19L to 38L). 2. Crank the engine for one to two s[...]

CAUTION! Due to lack of lubricants in alcohol or gasoline, the use of these fuels can cause damage to the fuel system. NOTE: • A maximum blend of 5% biodiesel, meeting ASTM specification D-6751 may be used with your Cum- mins 威 diesel engine. Use of biodiesel mixture in excess of 5% can negatively impact the on-engine fuel filter’s ability to[...]

Additionally , the overhead console in your vehicle has the ability to alert you to additional maintenance re- quired on your tr uck or engine. Refer to the following messages that may be displayed on your Electronic V ehicle Information Center (EVIC): W ARNING! A hot exhaust system can start a fire if you park over materials that can burn. Such ma[...]

By simply driving your vehicle at highway speeds for as little as 45 minutes, you can remedy the condition in the particulate filter system and allow your Cummins 威 diesel engine and exhaust after-tr eatment system to remove the trapped PM and restor e the system to normal operating condition. Exhaust Filter XX% Full Indicates that the Diesel Par[...]

CAUTION! See your authorized dealer , as damage to the exhaust system could occur soon with continued operation. Maintenance-Free Batteries The top of the maintenance-free batteries ar e perma- nently sealed. Y ou will never have to add water , nor is periodic maintenance requir ed. NOTE: Replacement batteries should both be of equal capacity to pr[...]

Battery Blanket Usage A battery loses 60% of its cranking power as the battery temperature decr eases to 0°F (-18°). For the same de- crease in temperatur e, the engine requires twice as much power to crank at the same RPM. The use of 120 V olt AC powered battery blankets will gr eatly increase starting capability at low temperatures. Suitable ba[...]

If the cap is sealing properly , the engine coolant (anti- freeze) will begin to drain fr om the coolant recovery bottle. DO NOT REMOVE THE COOLANT PRESSURE CAP WHEN THE COOLING SYSTEM IS HOT . Cooling System — Drain, Flush and Refill Refer to the “Maintenance Schedule” in Section 8 of this manual for the proper maintenance intervals. If the [...]

CAUTION! (Continued) • This vehicle has not been designed for use with Propylene Glycol based engine coolant (anti- freeze). Use of Propylene Glycol based engine coolant (antifreeze) is not recommended. Adding Coolant Y our vehicle has been built with an improved engine coolant (antifreeze) that allows extended maintenance intervals. This engine [...]

Please note that it is the owner’s responsibility to main- tain the proper level of pr otection against freezing ac- cording to the temperatur es occurring in the area where the vehicle is operated. NOTE: Mixing engine coolant (antifreeze) types will decrease the life of the engine coolant (antifr eeze) and will requir e more frequent engine cool[...]

rules for your community . T o prevent ingestion by ani- mals or children, do not stor e ethylene glycol based engine coolant (antifreeze) in open containers or allow it to remain in puddles on the gr ound. If ingested by a child, contact a physician immediately . Clean up any ground spills immediately . Coolant Level The coolant bottle provides a [...]

• Do not overfill the coolant recovery bottle. • Check the engine coolant (antifreeze) fr eeze point in the radiator and in the coolant recovery bottle. If engine coolant (antifreeze) needs to be added, the contents of the coolant recovery bottle must also be protected against fr eezing. • If frequent engine coolant (antifr eeze) additions ar[...]

(10° to 38°C). This cooling process enables mor e efficient burning of fuel resulting in fewer emissions. T o guarantee optimum performance of the system, keep the surfaces of the charge air cooler , condenser and radiator clean and free of debris. Periodically check the hoses leading to and from the char ge air cooler for cracks or loose clamps [...]

Use only brake fluid that has been in a tightly closed or sealed container to avoid contamination from for eign matter or moisture. CAUTION! Do not allow a petroleum-based fluid to contaminate the brake fluid. Seal damage and loss of brake performance may result. Clutch Hydraulic System The clutch hydraulic system is a sealed maintenance-free syste[...]

Automatic T ransmission — If Equipped Lubricant Selection Refer to “Fluids, Lubricants and Genuine Parts” in this section for the correct fluid type. Fluid Level Check— 68RFE (Ram T ruck Only) If your vehicle is equipped with a dipstick, use the following procedur e. If your vehicle has a capped dip- stick tube, it is sealed and should not [...]

requir ed into the dipstick tube. Do not overfill. After adding any quantity of oil through the oil fill tube, wait a minimum of two minutes for the oil to fully drain into the transmission before r echecking the fluid level. NOTE: If it is necessary to check the transmission below the operating temperature, the fluid level should be between the tw[...]

Fluid Level Check — AS68RC (Chassis Cab Only) Check the fluid level while the transmission is at normal operating temperature. This occurs after at least 15 miles (25 km) of driving. At normal operating temperature, the fluid cannot be held comfortably between the fingertips. T o properly check the transmission fluid, the following procedur e mus[...]

the dipstick tube, wait a minimum of two minutes for the oil to fully drain into the transmission before r echecking the fluid level. NOTE: If it is necessary to check the transmission below the operating temperature, the fluid level should be between the two COLD (lower) holes on the dipstick with the fluid at approximately 70°F to 85°F (20°C t[...]

Noise Control System Required Maintenance & W arranty All vehicles built over 10,000 lbs. (4 535 kg) Gross V ehicle W eight Rating and manufactured for sale and use in the United States are r equired to comply with the Federal Government’s Exterior Noise Regulations. These vehicles can be identified by the Noise Emission Control Label located[...]

or suspected. Proper maintenance of the entir e vehicle will help the effectiveness of the noise contr ol 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, burned or blown out mufflers, burned or r usted out[...]

• 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 W arranty The manufacturer warrants that this vehicle as manufac- tured by the manufactur er , was designed,[...]

Maintenance Log and Service Chart (Diesel Engines) Noise Systems Maintenance Chart and Service Log — Insert Month, Day , Y ear 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 60 000 72 000 84 000 96 000 Exhaust system-in[...]

FLUID CAP ACITIES U.S. Metric Engine Oil with Filter 6.7L T urbo Diesel Engine 12 Quarts 1 1.4 Liters Cooling System 6.7L T urbo Diesel Engine (MOP AR 威 Engine Coolant/ Antifreeze 5 Y ear/100,000 Mile Formula) 5.7 Gallons 21.4 Liters 1 16 MAINT AINING YOUR VEHICLE[...]

FLUIDS, LUBRICANTS AND GENUINE P ARTS Engine Component Fluid, Lubricant, or Genuine Part Engine Coolant MOP AR 威 Antifreeze/Coolant 5 Y ear/100,000 Mile Formula HOA T (Hybrid Organic Additive T echnology) Engine Oil (6.7L T urbo Diesel Engine) In ambient temperatures below 0°F (-18°C), 5W -40 synthetic engine oil that meets Chrysler Materials S[...]

Component Fluid, Lubricant, or Genuine Part Crankcase V entilation Filter (6.7L T urbo Diesel Engine) MOP AR 威 CCV Filter or equivalent Fuel Selection (6.7L T urbo Diesel Engine) Use good quality diesel fuel from a r eputable supplier in your vehicle. Federal law requir es that you must fuel this vehicle with Ultra Low Sulfur Highway Diesel fuel [...]

Chassis Component Fluid, Lubricant, or Genuine Part Automatic T ransmission (6-Speed 68RFE) (Ram T ruck Only) MOP AR 威 A TF+4 Automatic T ransmission Fluid Automatic T ransmission (6-Speed AS68RC) (Chassis Cab Only) MOP AR 威 AS68RC Automatic T ransmission Fluid Clutch Linkage MOP AR 威 Multi-Purpose Grease, NLGI Grade 2 E.P . or equivalent Man[...]

[...]

MAINTENANCE SCHEDULES CONTENTS 䡵 Maintenance Schedule ................. 1 2 2 ▫ Oil Change Indicator System ........... 1 2 3 ▫ Perform Service Indicator ............. 1 2 4 ▫ Required Maintenance Intervals ......... 1 2 4 8[...]

MAINTENANCE SCHEDULE CAUTION! Failure to perform the required maintenance items may result in damage to the vehicle. At Each Stop for Fuel • Check the engine oil level about 30 minutes after a fully warmed engine is shut off. Checking the oil level while the vehicle is on level ground will impr ove the accuracy of the oil level reading. Add oil o[...]

Oil Change Indicator System Ram T ruck Pick-Up (2500 and 3500 Models) Y our vehicle is equipped with an engine oil change indicator system. This system will alert you when it is time to change your engine oil by displaying the words “Oil Change Required” on your Electr onic V ehicle Infor- mation Center (EVIC). The engine oil change indicator s[...]

Ram T ruck Chassis Cab (3500, 4500, and 5500 Models) Replace the engine oil and oil filter every 7,500 miles (12 000 km) or six months, or sooner if prompted by the oil change indicator system (if equipped). Under no circumstances should oil change intervals exceed 7,500 miles (12 000 km) or six months, whichever comes first. Perform Service Indica[...]

7,500 Miles (12,000 km) or 6 Months Maintenance Service Schedule ❏ When prompted by the Engine Oil Indicator System, the engine oil and filter must be changed. If not prompted by the Engine Oil Indicator System within 7,500 miles (12 000 km) or 6 months since the last oil and filter change, change the engine oil and engine oil filter . Under no c[...]

15,000 Miles (24,000 km) or 12 Months Maintenance Service Schedule ❏ When prompted by the Engine Oil Indicator System, the engine oil and filter must be changed. If not prompted by the Engine Oil Indicator System within 7,500 miles (12 000 km) or 6 months since the last oil and filter change, change the engine oil and engine oil filter . Under no[...]

22,500 Miles (36,000 km) or 18 Months Maintenance Service Schedule ❏ When prompted by the Engine Oil Indicator System, the engine oil and filter must be changed. If not prompted by the Engine Oil Indicator System within 7,500 miles (12 000 km) or 6 months since the last oil and filter change, change the engine oil and engine oil filter . Under no[...]

30,000 Miles (48,000 km) or 24 Months Maintenance Service Schedule ❏ When prompted by the Engine Oil Indicator System, the engine oil and filter must be changed. If not prompted by the Engine Oil Indicator System within 7,500 miles (12 000 km) or 6 months since the last oil and filter change, change the engine oil and engine oil filter . Under no[...]

37,500 Miles (60,000 km) or 30 Months Maintenance Service Schedule ❏ When prompted by the Engine Oil Indicator System, the engine oil and filter must be changed. If not prompted by the Engine Oil Indicator System within 7,500 miles (12 000 km) or 6 months since the last oil and filter change, change the engine oil and engine oil filter . Under no[...]

45,000 Miles (72,000 km) or 36 Months Maintenance Service Schedule ❏ When prompted by the Engine Oil Indicator System, the engine oil and filter must be changed. If not prompted by the Engine Oil Indicator System within 7,500 miles (12 000 km) or 6 months since the last oil and filter change, change the engine oil and engine oil filter . Under no[...]

52,500 Miles (84,000 km) or 42 Months Maintenance Service Schedule ❏ When prompted by the Engine Oil Indicator System, the engine oil and filter must be changed. If not prompted by the Engine Oil Indicator System within 7,500 miles (12 000 km) or 6 months since the last oil and filter change, change the engine oil and engine oil filter . Under no[...]

60,000 Miles (96,000 km) or 48 Months Maintenance Service Schedule ❏ When prompted by the Engine Oil Indicator System, the engine oil and filter must be changed. If not prompted by the Engine Oil Indicator System within 7,500 miles (12 000 km) or 6 months since the last oil and filter change, change the engine oil and engine oil filter . Under no[...]

67,500 Miles (108,000 km) or 54 Months Maintenance Service Schedule ❏ When prompted by the Engine Oil Indicator System, the engine oil and filter must be changed. If not prompted by the Engine Oil Indicator System within 7,500 miles (12 000 km) or 6 months since the last oil and filter change, change the engine oil and engine oil filter . Under n[...]

75,000 Miles (120,000 km) or 60 Months Maintenance Service Schedule ❏ When prompted by the Engine Oil Indicator System, the engine oil and filter must be changed. If not prompted by the Engine Oil Indicator System within 7,500 miles (12 000 km) or 6 months since the last oil and filter change, change the engine oil and engine oil filter . Under n[...]

82,500 Miles (132,000 km) or 66 Months Maintenance Service Schedule ❏ When prompted by the Engine Oil Indicator System, the engine oil and filter must be changed. If not prompted by the Engine Oil Indicator System within 7,500 miles (12 000 km) or 6 months since the last oil and filter change, change the engine oil and engine oil filter . Under n[...]

90,000 Miles (144,000 km) or 72 Months Maintenance Service Schedule ❏ When prompted by the Engine Oil Indicator System, the engine oil and filter must be changed. If not prompted by the Engine Oil Indicator System within 7,500 miles (12 000 km) or 6 months since the last oil and filter change, change the engine oil and engine oil filter . Under n[...]

97,500 Miles (156,000 km) or 78 Months Maintenance Service Schedule ❏ When prompted by the Engine Oil Indicator System, the engine oil and filter must be changed. If not prompted by the Engine Oil Indicator System within 7,500 miles (12 000 km) or 6 months since the last oil and filter change, change the engine oil and engine oil filter . Under n[...]

105,000 Miles (168,000 km) or 84 Months Maintenance Service Schedule ❏ When prompted by the Engine Oil Indicator System, the engine oil and filter must be changed. If not prompted by the Engine Oil Indicator System within 7,500 miles (12 000 km) or 6 months since the last oil and filter change, change the engine oil and engine oil filter . Under [...]

1 12,500 Miles (180,000 km) or 90 Months Maintenance Service Schedule ❏ When prompted by the Engine Oil Indicator System, the engine oil and filter must be changed. If not prompted by the Engine Oil Indicator System within 7,500 miles (12 000 km) or 6 months since the last oil and filter change, change the engine oil and engine oil filter . Under[...]

120,000 Miles (192,000 km) or 96 Months Maintenance Service Schedule ❏ When prompted by the Engine Oil Indicator System, the engine oil and filter must be changed. If not prompted by the Engine Oil Indicator System within 7,500 miles (12 000 km) or 6 months since the last oil and filter change, change the engine oil and engine oil filter . Under [...]

127,500 Miles (204,000 km) or 102 Months Maintenance Service Schedule ❏ When prompted by the Engine Oil Indicator System, the engine oil and filter must be changed. If not prompted by the Engine Oil Indicator System within 7,500 miles (12 000 km) or 6 months since the last oil and filter change, change the engine oil and engine oil filter . Under[...]

135,000 Miles (216,000 km) or 108 Months Maintenance Service Schedule ❏ When prompted by the Engine Oil Indicator System, the engine oil and filter must be changed. If not prompted by the Engine Oil Indicator System within 7,500 miles (12 000 km) or 6 months since the last oil and filter change, change the engine oil and engine oil filter . Under[...]

142,500 Miles (228,000 km) or 1 14 Months Maintenance Service Schedule ❏ When prompted by the Engine Oil Indicator System, the engine oil and filter must be changed. If not prompted by the Engine Oil Indicator System within 7,500 miles (12 000 km) or 6 months since the last oil and filter change, change the engine oil and engine oil filter . Unde[...]

150,000 Miles (240,000 km) or 120 Months Maintenance Service Schedule ❏ When prompted by the Engine Oil Indicator System, the engine oil and filter must be changed. If not prompted by the Engine Oil Indicator System within 7,500 miles (12 000 km) or 6 months since the last oil and filter change, change the engine oil and engine oil filter . Under[...]

Inspection and service should also be performed anytime a malfunction is observed or suspected. Retain all receipts. * This maintenance is not requir ed if belt was previously replaced. **The EGR V alve and EGR Cooler maintenance will be covered by the manufactur er only at this maintenance interval, for vehicles in California, Maine, Massachusetts[...]

[...]

INDEX 9[...]

Adding Fuel ............................ 7 4 Air Cleaner , Engine (Engine Air Cleaner Filter) ............... 90,1 13 Air Filter .............................. 9 0 Airbag Light ............................ 2 5 Alarm (Security Alarm) .................... 2 7 Antifreeze (Engine Coolant) .............. 101,102 Capacities ........................... 1 [...]

Check Engine Light (Malfunction Indicator Light) ................ 2 9 Compass Calibration ...................... 1 8 Compass V ariance ........................ 1 9 Console, Overhead ....................... 1 0 Coolant Pressur e Cap (Radiator Cap) .......... 1 0 3 Cooling System ......................... 1 0 0 Adding Coolant (Antifreeze) ...........[...]

Break-In Recommendations ................. 6 Compartment ......................... 8 5 Coolant (Antifreeze) .................... 1 1 7 Identification .......................... 8 5 Idling ............................... 4 7 Jump Starting ......................... 7 8 O i l .............................. 86,1 17 Oil Filler Cap ......................[...]

Oil Pressur e ........................... 2 6 Speedometer .......................... 2 5 T achometer ........................... 2 5 V oltmeter .......................... 24,44 Gear Ranges ........................ 55,60,67 Information Center ....................... 1 1 Information Center , V ehicle .................. 1 1 Instrument Cluster ........[...]

Lubricant Selection ..................... 1 1 9 Shift Speeds ........................... 6 7 Map/Reading Lights ...................... 1 0 New V ehicle Break-In Period ................. 6 Noise Control Maintenance .......................... 1 1 2 T ampering Prohibited ................... 1 1 3 Noise Emission W arranty ............... 1 12,1 14 Odom[...]

Radiator Cap (Coolant Pressur e Cap) ....... 101,103 Resetting Oil Change Indicator ............... 1 3 Resetting Perform Service Indicator ........... 1 2 4 Seat Belts Reminder ............................ 2 5 Security Alarm (Theft Alarm) ................ 2 7 Selection of Coolant (Antifreeze) .......... 101,1 17 Settings, Personal ................[...]

T rip Odometer ........................ 27,35 T urn Signals ............................ 2 5 V ariance, Compass ....................... 1 9 V ehicle Information Center .................. 1 1 V iscosity , Engine Oil ...................... 8 8 V oltmeter ............................ 24,44 W arning Lights (Instrument Cluster Description) ... 2 4 W ate[...]

INTRODUCTION A MESSAGE FROM CHRYSLER LLC THINGS TO KNOW BEFORE ST ARTING YOUR VEHICLE STEERING WHEEL LOCK - IF EQUIPPED To Manually Lock the Steering WheelT o Release the Steering Wheel LockENGINE BREAK-IN RECOMMENDATIONS UNDERST ANDING THE FEATURES OF YOUR VEHICLE OVERHEAD CONSOLE WITH ELECTRONIC VEHICLE INFORMATION CENTER (EVIC) Dome/Reading Ligh[...]

INST ALLA TION OF RADIO TRANSMITTING EQUIPMENT Special design considerations are incorporated into this vehicle’s electronic system to pr ovide immunity to radio frequency signals. Mobile two-way radios and telephone equipment must be installed properly by trained person- nel. The following must be observed during installation. The positive power[...]

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