2007 DODGE RAM 2500 DIESEL maintenance

MAINTAINING YOUR VEHICLE
CONTENTS

Engine Compartment ....................378
▫ 5.9L HO Cummins Turbo Diesel ...........378

Onboard Diagnostic System (OBD II) .........379

Replacement Parts ......................379

Engine Data Plate ......................380

Dealer Service .........................380

Service Information .....................380

Maintenance Procedures ..................383
▫ Engine Oil ..........................383 ▫
Drive Belt ...........................389
▫ Engine Air Cleaner Filter ................389
▫ Draining Fuel/Water Separator Filter .......391
▫ Maintenance Free Batteries ...............394
▫ Air Conditioner Maintenance .............396
▫ Power Steering — Fluid Check ............397
▫ Front Suspension Ball Joints ..............397
▫ Steering Linkage — Inspection ............398
▫ Front Prop Shaft Lubrication .............398
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▫Front Axle Universal Drive Joints And Pivot
Bearings ............................398
▫ Body Lubrication .....................399
▫ Windshield Wiper Blades ................399
▫ Windshield Washers ...................399
▫ Exhaust System ......................400
▫ Cooling System .......................401
▫ Fan ...............................407
▫ Charge Air Cooler (Inter-Cooler) ..........408
▫ Hoses And Vacuum/Vapor Harnesses .......408
▫ Brake System ........................409
▫ Clutch Linkage .......................411
▫ Clutch Hydraulic System ................411 ▫
Rear Axle And 4X4 Front Driving
Axle Fluid Level ......................411
▫ Transfer Case — If Equipped .............412
▫ Manual Transmission — If Equipped .......412
▫ Automatic Transmission ................413
▫ Front Wheel Bearings ..................415
▫ Selection Of Lubricating Grease ...........416
▫ Noise Control System Required Maintenance &
Warranty ...........................417
▫ Appearance Care And Protection
From Corrosion ......................422

Fuses (Integrated Power Module) ...........426

Vehicle Storage ........................431

Replacement Light Bulbs .................432
376 MAINTAINING YOUR VEHICLE

ONBOARD DIAGNOSTIC SYSTEM (OBD II)
Vehicles equipped with California emissions controls
have a sophisticated onboard diagnostic system called
OBDII. This system monitors the performance of the
emissions, engine, and automatic transmission control
systems. When these systems are operating properly,
your vehicle will provide excellent performance and fuel
economy, as well as engine emissions well within current
government regulations.
If any of these systems require service, the OBD II system
will turn on the “Malfunction Indicator Light.” It will
also store diagnostic codes and other information to
assist your service technician in making repairs. Al-
though your vehicle will usually be driveable and not
need towing, see your dealer for service as soon as
possible.CAUTION!
Prolonged driving with the “Malfunction Indicator
Light” on could cause further damage to the emis-
sion control system. It could also affect fuel economy
and driveability. The vehicle must be serviced before
any emissions tests can be performed.
If the “Malfunction Indicator Light” is flashing,
severe catalytic converter damage and power loss
will soon occur. Immediate service is required.
REPLACEMENT PARTS
Use of genuine Mopar parts for normal/scheduled
maintenance and repairs is highly recommended to in-
sure the designed performance. Damage or failures
caused by the use of non-Mopar parts for maintenance
and repairs will not be covered by the manufacturer’s
warranty.
MAINTAINING YOUR VEHICLE 379
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•If an engine has been operating and the coolant is hot,
allow the engine to cool before you slowly loosen the
filler cap and relieve the pressure from the cooling
system.
•To avoid burns, remember that the engine components
will stay hot after the engine is shut off.
•Do not use gasoline or other flammable materials to
clean parts. Always use approved cleaning solvents.
•Relieve all pressure in the fuel, oil and cooling systems
before any lines, fittings or related items are removed
or disconnected. Be alert for possible pressure when
disconnecting any device from a system that utilizes
pressure. Do not check for pressure leaks with your
hand. High pressure oil or fuel can cause personal
injury.
WARNING!
Do not open the high pressure fuel system with the
engine running. Engine operation causes high fuel
pressure. High pressure fuel spray can cause serious
injury or death.
•Important: All maintenance other than that listed in
this manual, as well as some procedures listed here,
MUST be performed by your local Dodge Truck
Dealer. Your authorized Dodge Dealer has been
trained and has the necessary parts to maintain your
engine.
382 MAINTAINING YOUR VEHICLE

MAINTENANCE PROCEDURES
The pages that follow contain therequiredmaintenance
services determined by the engineers who designed your
vehicle.
Besides the maintenance items for which there are fixed
maintenance intervals, there are other items that should
operate satisfactorily without periodic maintenance.
However, if a malfunction of these items does occur, it
could adversely affect the engine or vehicle performance.
These items should be inspected if a malfunction is
observed or suspected.
Engine Oil
Checking Oil Level
To assure proper lubrication of your vehicle’s engine, the
engine oil must be maintained at the correct level. Check
the oil level at regular intervals. The best time to check
the oil level is before starting the engine after it has been
parked overnight. When checking oil after operating the engine, first ensure the engine is at full operating tem-
perature, then wait at least 15 minutes after engine
shutdown to check the oil.
Checking the vehicle while it’s on level ground will also
improve the accuracy of the oil level readings. Add oil
only when the level on the dipstick is below the “ADD”
mark. The total capacity from the low mark to the high
mark is 2 quarts (1.9 liters).
CAUTION!
Overfilling or underfilling the crankcase will cause
oil aeration or loss of oil pressure. This could dam-
age your engine.
MAINTAINING YOUR VEHICLE 383
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You may use synthetic engine oils provided the recom-
mended oil quality requirements are met, and the recom-
mended maintenance intervals for oil and filter changes
are followed.
Materials Added to Engine Oil
The manufacture strongly recommends against the addi-
tion of any additives (other than leak detection dyes or lube odorants) to the engine oil. Engine oil is an engi-
neered product and it’s performance may be impaired by
supplemental additives.
NOTE:
The manufacturer offers a lube odorant (Mopar
Diesel Fresh) for diesel engines crankcases. The lube
odorant is recommended by the manufacturer to reduce
the sulfur smell that may occur during engine idling.
Engine Oil Filter
Refer to Fluids, Lubricants and Genuine Parts for the
correct part number. The engine oil filter should be
changed at everyengine oil change.
Engine Oil And Filter — Change
Operate the engine until the coolant temperature reaches
140°F (60°C). Shut the engine off. Remove the oil drain
plug.
Use a container that can hold at least 12 quarts (11.3
Liters) to hold the used oil.
386 MAINTAINING YOUR VEHICLE

WARNING!
Do not use alcohol or gasoline as a fuel blending
agent. They can be unstable under certain conditions
and be hazardous or explosive when mixed with
diesel fuel.
CAUTION!
Due to lack of lubricants in alcohol or gasoline, the
use of these fuels can cause damage to the fuel
system.
NOTE: A maximum blend of 5% biodiesel may be used
with your Cummins Diesel equipped Dodge Ram Truck NOTE:
As sufficient testing as not been completed,
ethanol blends are not recommended or approved for use
with your Cummins Diesel equipped Dodge Ram Truck.
NOTE: In addition, commercially available fuel addi-
tives are not necessary for the proper operation of your
Cummins Diesel equipped Dodge Ram Truck.
Maintenance Free Batteries
The top of the maintenance free batteries are perma-
nently sealed. You will never have to add water, nor is
periodic maintenance required.
NOTE: Replacement batteries should both be of equal
capacity to prevent damage to the vehicle’s charging
system.
394 MAINTAINING YOUR VEHICLE

Battery Blanket Usage
A battery loses 60% of its cranking power as the battery
temperature decreases to 0°F (-18°). For the same de-
crease in temperature, the engine requires twice as much
power to crank at the same RPM. The use of 120 VAC
powered battery blankets will greatly increase starting
capability at low temperatures. Suitable battery blankets
are available from your authorized Mopar dealer.
Air Conditioner Maintenance
For best possible performance, your air conditioner
should be checked and serviced by an Authorized Dealer
at the start of each warm season. This service should
include cleaning of the condenser fins and a performance
test. Drive belt tension should also be checked at this
time.
WARNING!
•Use only refrigerants and compressor lubricants
approved by the manufacturer for your air condi-
tioning system. Some unapproved refrigerants are
flammable and can explode, injuring you. Other
unapproved refrigerants or lubricants can cause
the system to fail, requiring costly repairs. Refer
to Section 3 of the Warranty Information book for
further warranty information.
•The air conditioning system contains refrigerant
under high pressure. To avoid risk of personal
injury or damage to the system, adding refrigerant
or any repair requiring lines to be disconnected
should be done by an experienced repairman.
396 MAINTAINING YOUR VEHICLE