2004 DODGE RAM 2500 DIESEL cooling

CAUTION!
Mixing of coolants other than specified (HOAT),
may result in engine damage that may not be cov-
ered under the new vehicle warranty, and decreased
corrosion protection. If a non-HOAT coolant is intro-
duced into the cooling system in an emergency, it
should be replaced with the specified coolant as
soon as possible.
Do not use plain water alone or alcohol base anti-
freeze products. Do not use additional rust inhibi-
tors or antirust products, as they may not be compat-
ible with the radiator coolant and may plug the
radiator.
This vehicle has not been designed for use with
Propylene Glycol based coolants. Use of Propylene
Glycol based coolants is not recommended.
Disposal Of Used Engine Coolant
Used ethylene glycol based engine coolant is a regulated
substance requiring proper disposal. Check with your
local authorities to determine the disposal rules for your
community. Do not store ethylene glycol-based engine
coolant in open containers or allow it to remain in
puddles on the ground. Prevent ingestion by animals and
children. If ingested by a child, contact a physician
immediately. Clean up any ground spills immediately.
Coolant Pressure Cap
The coolant pressure cap must be fully tightened to
prevent loss of coolant and to insure that coolant will
return to the radiator from the coolant reserve tank.
346 MAINTAINING YOUR VEHICLE

WARNING!
Never add coolant when the engine is overheated.
Do not loosen or remove the pressure cap to cool an
overheated engine. Heat causes pressure build up in
the cooling system. To prevent scalding or injury, do
not remove the pressure cap while the system is hot
or under pressure.
CAUTION!
Recheck the cooling system to insure total system is
full of coolant.
Fan
Inspection
Check the fan for cracks and bent or broken blades. If any
of these conditions exist, you must replace the fan. Make
sure it is securely mounted.
NOTE:This service procedure must be performed by a
trained service technician. Make arrangements with your
authorized Dodge Truck Dealer for this inspection.
Charge Air Cooler (Inter-Cooler)
The charge air cooler is positioned between the radiator
and the air conditioner condenser. Air enters the engine
through the air cleaner and passes through the turbo-
charger where it is pressurized. This pressurized air
rapidly reaches high temperature. The air is then directed
through a hose to the charge air cooler and through
another hose to the intake manifold of the engine. The air
entering the engine has been cooled by about 50 to 100
MAINTAINING YOUR VEHICLE 347
7

degrees Fahrenheit. This cooling process enables more
efficient burning of fuel resulting in fewer emissions.
To guarantee optimum performance of the system, keep
the surfaces of the charge air cooler, condenser and
radiator clean and free of debris. Periodically check the
hoses leading to and from the charge air cooler for cracks
or loose clamps resulting in loss of pressure and reduced
engine performance.
Hoses And Vacuum/Vapor Harnesses
Inspect surfaces of hoses and nylon tubing for evidence
of heat and mechanical damage. Hard or soft spots,
brittle rubber, cracking, tears, cuts, abrasions, and exces-
sive swelling indicate deterioration of the rubber.
Pay particular attention to those hoses nearest to high
heat sources such as the exhaust manifold. Inspect hose
routing to be sure hoses do not come in contact with any
heat source or moving component which may cause heat
damage or mechanical wear.Insure nylon tubing in these areas has not melted or
collapsed.
Inspect all hose connections such as clamps and cou-
plings to make sure they are secure and no leaks are
present.
Components should be replaced immediately if there is
any evidence of wear or damage that could cause failure.
Brake System
Power Disc Brakes (Front and Rear)
Disc brakes do not require adjustment; however, several
hard stops during the break-in period are recommended
to seat the linings and wear off any foreign material.
Brake Master Cylinder
The fluid level of the master cylinder should be checked
when performing under the hood service, or immedi-
ately if the brake system warning lamp indicates system
failure.
348 MAINTAINING YOUR VEHICLE

²AIR CLEANER
þRemoval of the air cleaner.
þRemoval of the air cleaner filter element from the air
cleaner housing.
þRemoval of the air ducting.
²EXHAUST SYSTEM
þRemoval or rendering inoperative exhaust system
components including the muffler or tailpipe.
²ENGINE COOLING SYSTEM
þRemoval or rendering inoperative the fan clutch.
þRemoval of the fan shroud.
Noise Emission Warranty
The manufacturer warrants that this vehicle as manufac-
tured by the manufacturer, was designed, built and
equipped to conform at the time it left the manufacturer's
control with all applicable U.S. EPA Noise Control Regu-
lations.
This warranty covers this vehicle as designed, built and
equipped by the manufacturer, and is not limited to any
particular part, component or system of the vehicle
manufactured by the manufacturer. Defects in design,
assembly or in any part, component or system of the
vehicle as manufactured by the manufacturer, which, at
the time it left the manufacturer's control, caused noise
emissions to exceed Federal standards, are covered by
this warranty for the life of the vehicle.
MAINTAINING YOUR VEHICLE 359
7

2. Pull bulb straight from the connector.
3. Reverse procedure for installation of bulbs and hous-
ing.FLUID CAPACITIES
FLUID CAPACITIES U.S. Metric
Fuel
2500 Shortbed Models 34 gal. 128L
2500 Longbed Models 35 gal. 132L
3500 Shortbed Models 34 gal. 128L
3500 Longbed Models 35 gal. 132L
Engine Oil
5.9L Diesel Engine I-6 12.0 qts. 11.4L
Cooling System
5.9L Diesel Engine I-6 7 gal. 26.5L
MAINTAINING YOUR VEHICLE 379
7

Child Seat............................56,62
Cigar Lighter........................... 127
Climate Control......................... 185
Clock................................ 151
Clutch Linkage Maintenance................ 350
Compact Disc Maintenance................. 184
Compact Disc Player..................158,164
Compact Spare Tire...................... 255
Compass.............................. 117
Compass Calibration..................... 117
Compass Variance....................... 118
Computer, Trip/Travel.................... 113
Console, Overhead....................... 112
Contract, Service........................ 404
Cooling System......................... 343
Coolant Capacity...................... 379
Coolant Level......................... 344
Disposal of Used Coolant................ 346
Drain, Flush, and Refill.................. 344Inspection........................... 343
Radiator Cap......................343,346
Selection of Coolant..................345,380
Temperature Gauge..................... 146
Cruise Control.......................... 109
Cup Holder............................ 128
Customer Assistance..................... 402
Daytime Running Lights................... 102
Dealer Service.......................... 322
Defroster, Rear Window..............78,191,195
Defroster, Windshield..................186,189
Delay Wipers........................... 105
Differential, Limited-Slip.................. 237
Dipsticks.............................. 325
Power Steering........................ 339
Disc Brakes............................ 348
Disposal.............................. 331
Engine Oil........................... 331
414 INDEX

Used Coolant......................... 346
Door Ajar............................. 145
Door Locks............................. 16
Door Opener, Garage..................... 120
Draining Fuel/Water Separator Filter.......... 334
Drive Belts............................ 331
Dual Rear Wheels.....................263,306
Electric Rear Window Defrost..........78,191,195
Electrical Power Outlets................... 126
Electronic Speed Control................... 109
Emergency Brake........................ 238
Emergency, In Case of
Freeing Vehicle When Stuck............... 313
Hazard Warning Flasher................. 296
Jacking............................. 300
Jump Starting......................... 310
Tow Hooks.......................... 314
Towing............................. 315Emission Control System Maintenance......... 384
Engine............................... 320
Air Cleaner.......................... 331
Block Heater.......................205,212
Break-In Recommendations................ 67
Compartment......................... 320
Coolant..........................345,380
Cooling............................. 343
Data Plate........................... 294
Identification......................... 320
Idling.............................. 214
Jump Starting......................... 310
Oil ..............................325,380
Oil Synthetic......................... 214
Runaway............................ 264
Temperature Gauge..................... 146
Ethylene Glycol Antifreeze................. 345
Exhaust Gas Caution................69,136,342
Exhaust System....................69,342,358
INDEX 415
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