2011 Ram 3500 maintenance

TABLE OF CONTENTSSECTIONPAGE
1INTRODUCTION............................................................3
2THINGS TO KNOW BEFORE STARTING YOUR VEHICLE..............................5
3UNDERSTANDING YOUR INSTRUMENT PANEL.................................... 9
4STARTING AND OPERATING.................................................41
5WHAT TO DO IN EMERGENCIES.............................................. 89
6MAINTAINING YOUR VEHICLE...............................................95
7MAINTENANCE SCHEDULES.................................................135
8INDEX...................................................................161
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A MESSAGE FROM CHRYSLER GROUP LLC
Chrysler Group LLC and Cumminswelcome 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 trucks in the United
States and Canada are diesel-powered because of the fuel
economy, rugged durability, and high torque which per-
mits pulling heavy loads. Cummins engines power well
over half of these trucks. Now this same technology and
proven performance is yours in your truck equipped
with the Cummins turbocharged diesel engine.
You may find that some of the starting, operating, and
maintenance procedures are different. However, they are
simple to follow and careful adherence to them will
ensure that you take full advantage of the features of this
engine. NOTE:
Some aftermarket products may cause severe
engine/transmission and/or exhaust system damage.
Your vehicle’s Powertrain Control Systems can detect
and store information about vehicle modifications that
increase horsepower and torque output such as whether
or not performance-enhancing powertrain components,
commonly referred to as downloaders, power boxes, or
performance chips have been used.
This information cannot be erased and will stay in the
system’s memory even if the modification is removed.
This information can be retrieved by Chrysler Group
LLC, and service and repair facilities, when servicing
your vehicle. This information may be used to determine
if repair will be covered by 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 the vehicle to it’s
factory settings.
4 INTRODUCTION

As an added safety feature, your vehicle has been
equipped with a Tire Pressure Monitoring System
(TPMS) that illuminates a low tire pressure telltale when
one or more of your tires is significantly under-inflated.
Accordingly, when the low tire pressure telltale illumi-
nates, you should stop and check your tires as soon as
possible, and inflate them to the proper pressure. Driving
on a significantly under-inflated tire causes the tire to
overheat and can lead to tire failure. Under-inflation also
reduces fuel efficiency and tire tread life, and may affect
the vehicle’s handling and stopping ability.
Please note that the TPMS is not a substitute for proper
tire maintenance, and it is the driver ’s responsibility to
maintain correct tire pressure, even if under-inflation has
not reached the level to trigger illumination of the TPMS
low tire pressure telltale.
Your vehicle has also been equipped with a TPMS
malfunction indicator to indicate when the system is notoperating properly. The TPMS malfunction indicator is
combined with the low tire pressure telltale. When the
system detects a malfunction, the telltale will flash for
approximately one minute and then remain continuously
illuminated. This sequence will continue upon subse-
quent vehicle start-ups as long as the malfunction exists.
When the malfunction indicator is illuminated, the sys-
tem may not be able to detect or signal low tire pressure
as intended. TPMS malfunctions may occur for a variety
of reasons, including the installation of replacement or
alternate tires or wheels on the vehicle that prevent the
TPMS from functioning properly. Always check the
TPMS malfunction telltale after replacing one or more
tires or wheels on your vehicle, to ensure that the
replacement or alternate tires and wheels allow the TPMS
to continue to function properly.
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UNDERSTANDING YOUR INSTRUMENT PANEL 17

•Water In Fuel Indicator LightThe “Water In Fuel Indicator Light” will illu-
minate when there is water detected in the fuel
filter. If this light remains on, DO NOT start the
vehicle before you drain the water from the
fuel filter to prevent engine damage. Refer to “Mainte-
nance Procedures/ Draining Fuel/Water Separator Fil-
ter” in “Maintaining Your Vehicle” for further informa-
tion.
•Wait To Start Light The “Wait To Start Light” will illuminate when the
ignition is turned to the RUN position and the
intake manifold temperature is below 66°F (19°C). Wait
until the “Wait To Start Light” turns OFF, then start the
vehicle. Refer to “Starting Procedures” in “Starting and
Operating” for further information.
NOTE: The “Wait To Start Light” may not illuminate if
the intake manifold temperature is warm enough.
Oil Change Due
Your vehicle is equipped with an engine oil change
indicator system. The “Oil Change Due” message will
flash in the EVIC display for approximately 10 seconds
after a single chime has sounded to indicate the next
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.
Unless reset, this message will continue to display each
time you turn the ignition switch to the ON position. To
turn off the message temporarily, press and release the
RETURN button. To reset the oil change indicator system
(after performing the scheduled maintenance) perform
the following steps.
1. Turn the ignition switch to the ON position. (Do not
start the engine)
2. Fully press the accelerator pedal slowly three times
within 10 seconds.
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UNDERSTANDING YOUR INSTRUMENT PANEL 27

NOTE:The engine block heater cord is a factory in-
stalled option. If your vehicle is not equipped, heater
cords are available from your authorized MOPAR
dealer.
•A 12 Volt heater built into the fuel filter housing aids in
preventing fuel gelling. It is controlled 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
Temperature Above 66°F (19°C)
Observe the instrument panel cluster lights when starting
the engine.
1. Always apply the parking brake. 2. Shift into PARK for an automatic transmission. For
vehicles equipped with a manual transmission, fully
press and hold the clutch pedal and shift into NEUTRAL.
3. Turn the ignition switch to the ON position and watch
the instrument panel cluster lights.
CAUTION!
If the “Water in Fuel Indicator Light” remains on, DO
NOT START the engine before you drain the water
from the fuel filter to avoid engine damage. Refer to
“Maintenance Procedures/Draining Fuel/Water Sepa-
rator Filter” in “Maintaining Your Vehicle” for fur-
ther information.
4. Turn the ignition switch to the START position and
crank the engine. Do not press the accelerator during
starting.
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STARTING AND OPERATING 45

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.
5. When the engine starts, release the key fob.
6. Check to see that there is oil pressure.
7. Release the parking brake.
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) does not necessarily
reflect the engine manifold air temperature. Refer to “Electronic Vehicle Information Center (EVIC)” in “Un-
derstanding Your Instrument Panel” for further informa-
tion. When engine temperatures fall below 66°F (19°C)
the “Wait To Start Light” will remain on indicating the
intake manifold heater system is active.
Follow the steps in the “Normal Starting” procedure
except:
1. The “Wait To Start Light” will remain on for a period
of time (length of time depends on engine temperature).
CAUTION!
If the “Water in Fuel Indicator Light” remains on, DO
NOT START engine before you drain the water from
the fuel filter to avoid engine damage. Refer to
“Maintenance Procedures/Draining Fuel/Water Sepa-
rator Filter” in “Maintaining Your Vehicle” for fur-
ther information.
46 STARTING AND OPERATING

•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 your engine has run out of fuel, refer to
“Maintenance Procedures/Priming If The Engine Has
Run Out Of Fuel” in “Maintaining Your Vehicle” for
further information.
Starting Fluids
WARNING!
Starting fluids or flammable liquids are never to be
used in the Cumminsdiesel engine (see Warning
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 and
explosion causing serious personal injury and engine
damage. The engine is equipped with an automatic electric air
preheating system. If the instructions in this manual are
followed, the engine should start in all conditions.
WARNING!
Do not leave children or animals inside parked
vehicles in hot weather. Interior heat build up may
cause serious injury or death.
NORMAL OPERATION – DIESEL ENGINE
Observe the following when the engine is operating.
•All message center lights are off.
•Malfunction Indicator Light (MIL) is off.
•Engine oil pressure is above 10 psi (69 kPa) at idle.
•Voltmeter operation:
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STARTING AND OPERATING 49

•The engine requires the use of“Ultra Low Sulfur
Diesel Fuel”. Use of incorrect fuel could result in
engine and exhaust system damage. Refer to “Fuel
Requirements” in “Starting and Operating” for further
information.
Engine Oil Usage
Refer to “Maintenance Procedures” in “Maintaining Your
Vehicle” for the correct engine oil viscosity.
Winter Front Usage
If a winter front or cold weather cover is to be used, a
percentage of the total grille opening area must be left
uncovered to provide sufficient air flow to the charge air
cooler and automatic transmission oil cooler. The per-
centage of opening must be increased with the increasing
ambient air temperature and/or engine load. If the
cooling fan can be heard cycling frequently, increase the
size of the opening in the winter front. A suitable cold
weather cover is available from your MOPAR dealer.
Battery Blanket Usage
A battery loses 60% of its cranking power as the battery
temperature decreases to 0°F (-18°C). For the same de-
crease in temperature, the engine requires twice as much
power to crank at the same RPM. The use of 120 VAC
powered battery blankets will greatly increase starting
capability at low temperatures. Suitable battery blankets
are available from your authorized MOPARdealer.
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 oil pressure to
stabilize as the engine warms up.
NOTE:High-speed, no-load running of a cold engine
can result in excessive white smoke and poor engine
performance. No-load engine speeds should be kept
under 1,200 RPM during the warm-up period, especially
in cold ambient temperature conditions.
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STARTING AND OPERATING 51