UNDERBODY MOUNTED FUEL FILTER/WATER SEPARATOR
Draining Fuel/Water Separator
•If the “Water in Fuel” indicator lightis illuminated and an audible chime is
heard five times, you should stop the engine and drain the water from the separator.
• The drain is located on the bottom of the Fuel Filter and Water Separator assembly which is located in front of the rear axle above the drive shaft on pick up models.
The Chassis Cab models second filter location is on the frame behind the front
axle. The best access to this water drain valve is from under the vehicle.
• Turn the drain valve (located on the side of the filter) counterclockwise 1 full turn, then turn the ignition switch to the ON/RUN position to allow any accumulated
water to drain.
• When clean fuel is visible, close the drain and switch the ignition to OFF.
• Refer to the Diesel Supplement on the DVD for further details.
Underbody Fuel Filter Replacement
• With the engine off and a drain pan under the fuel filter drain hose, open the water drain valve 1 full turn counterclockwise and completely drain fuel and water into
the approved container.
• Close the water drain valve and remove the lid using a socket or strap wrench; rotate counterclockwise for removal. Remove the used o-ring and discard it.
• Remove the used filter cartridge from the housing and dispose of according to your local regulations.
• Wipe clean the sealing surfaces of the lid and housing and install the new o-ring into ring groove on the filter housing and lubricate with clean engine oil.
• Install a new filter in the housing. Push down on the cartridge to ensure it is properly seated. Do not pre-fill the filter housing with fuel.
• Start the engine and confirm no leaks are present.
The underbody mounted filter housing will cause the engine not to run if:
1. No filter is installed.
NOTE:
• Using a fuel filter that does not meet the manufacturer's filtration and water separating requirements can severely impact fuel system life and reliability.
• The WIF sensor is re-usable. Service kit comes with new o-ring for filter canister and WIF sensor.
6.7L CUMMINS® DIESEL
160
WARNING!
A hot engine cooling system is dangerous. You or others could be badly burned by
steam or boiling coolant.
BRAKE- Brake Warning Light
This light monitors various brake functions, including brake fluid level and parking
brake application. If the brake light turns on it may indicate that the parking brake is
applied, that the brake fluid level is low, or that there is a problem with the anti-lock
brake system reservoir.
If the light remains on when the parking brake has been disengaged, and the fluid
level is at the full mark on the master cylinder reservoir, it indicates a possible brake
hydraulic system malfunction or that a problem with the Brake Booster has been
detected by the Anti-Lock Brake System (ABS)/Electronic Stability Control (ESC)
system. In this case, the light will remain on until the condition has been corrected.
If the problem is related to the brake booster, the ABS pump will run when applying
the brake and a brake pedal pulsation may be felt during each stop.
The dual brake system provides a reserve braking capacity in the event of a failure to
a portion of the hydraulic system. A leak in either half of the dual brake system is
indicated by the Brake Warning Light, which will turn on when the brake fluid level
in the master cylinder has dropped below a specified level. The light will remain on
until the cause is corrected.
Vehicles equipped with the Anti-Lock Brake System (ABS), are also equipped with
Electronic Brake Force Distribution (EBD). In the event of an EBD failure, the Brake
Warning Light will turn on along with the ABS Light. Immediate repair to the ABS
system is required.
Operation of the Brake Warning Light can be checked by turning the ignition switch
from the OFF position to the ON/RUN position. The light should illuminate for
approximately two seconds. The light should then turn off unless the parking brake
is applied or a brake fault is detected. If the light does not illuminate, have the light
inspected by an authorized dealer.
The light also will turn on when the parking brake is applied with the ignition switch
in the ON/RUN position.
NOTE:
This light shows only that the parking brake is applied. It does not show the degree
of brake application.
WARNING!
Driving a vehicle with the red brake light on is dangerous. Part of the brake system
may have failed. It will take longer to stop the vehicle. You could have a collision.
Have the vehicle checked immediately.
WHAT TO DO IN EMERGENCIES
171
- Malfunction Indicator Light (MIL)
The Malfunction Indicator Light (MIL) is part of an onboard diagnostic system called
OBD II that monitors engine and automatic transmission control systems. The light
will illuminate when the key is in the ON/RUN position before engine start. If the bulb
does not come on when turning the key from OFF to ON/RUN, have the condition
checked promptly.
Certain conditions, poor fuel quality, etc., may illuminate the light after engine start.
The vehicle should be serviced if the light stays on through several of your typical driving
cycles. In most situations, the vehicle will drive normally and will not require towing.
CAUTION!
Prolonged driving with the Malfunction Indicator Light (MIL) on could cause damage
to the engine control system. It also could affect fuel economy and driveability. If the
MIL is flashing, severe catalytic converter damage and power loss will soon occur.
Immediate service is required.
WARNING!
A malfunctioning catalytic converter, as referenced above, can reach higher tempera-
tures than in normal operating conditions. This can cause a fire if you drive slowly or
park over flammable substances such as dry plants, wood, cardboard, etc. This could
result in death or serious injury to the driver, occupants or others.
- Electronic Stability Control (ESC) OFF Indicator Light
The ESC OFF indicator will illuminate when the Electronic Stability Control (ESC) is
turned off.
- Charging System Light
This light shows the status of the electrical charging system. If the charging system light
remains on, it means that the vehicle is experiencing a problem with the charging
system.
We recommend you do not continue driving if the charging system light is on. Have
the vehicle serviced immediately.
- Oil Pressure Warning Light
This light indicates low engine oil pressure. If the light turns on while driving, stop
the vehicle and shut off the engine as soon as possible. A chime will sound for four
minutes when this light turns on.
We recommend you do not operate the vehicle or engine damage will occur. Have the
vehicle serviced immediately.
WHAT TO DO IN EMERGENCIES
172
- Transmission Temperature Warning Light
This light indicates that there is excessive transmission fluid temperature that might
occur with severe usage such as trailer towing. If this light turns on, stop the vehicle
and run the engine at idle, with the transmission in NEUTRAL, until the light turns
off. Once the light turns off, you may continue to drive normally.
CAUTION!
Continuous driving with the Transmission Temperature 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 illuminated you could cause the fluid to boil over, come in contact with hot
engine or exhaust components and cause a fire.
OIL CHANGE EVIC INDICATOR
Message
If an “oil change” message (shown as “Change Oil Soon” and “Oil Change Needed”)
appears and a single chime sounds, it is time for your next required oil change.
Resetting The Light After Servicing
1. Turn the ignition switch to the ON/RUN position (do not start engine).
2. Fully depress the accelerator pedal three times within 10 seconds.
3. Turn the ignition switch to the OFF/LOCK position.
- Low Coolant Level Indicator Light
This light indicates low coolant level. If the light turns on while driving, stop the
vehicle and shut off the engine as soon as possible.
We recommend you do not operate the vehicle or engine damage will occur. Have the
vehicle serviced immediately.
WHAT TO DO IN EMERGENCIES
174
•For 4x2 and 4x4 trucks, when changing a rear wheel, assemble the jack drive tube
to the jack and connect the drive tube to the extension tube. Place the jack under
the axle between the spring and the shock absorber with the drive tubes extending
to the rear.
• Connect the jack tube extension and wheel wrench.
NOTE:
If the bottle jack will not lower by turning the dial (thumbwheel) by hand, it may be
necessary to use the jack drive tube in order to lower the jack.
• By rotating the wheel wrench clockwise, raise the vehicle until the wheel just clears the surface.
• Remove the wheel nuts and pull the wheel off. On single rear-wheel (SRW) trucks, install the spare wheel and wheel nuts with the cone shaped end of the wheel nuts
toward the wheel. On 3500 dual rear-wheel models (DRW) the wheel nuts are a
two-piece assembly with a flat face. Lightly tighten the wheel nuts. To avoid the
risk of forcing the vehicle off the jack, do not fully tighten the wheel nuts until the
vehicle has been lowered.
• Using the lug wrench, finish tightening the wheel nuts using a crisscross pattern. The correct wheel nut tightness is 130 ft lbs (176 N·m) torque (1500 Series),
135 ft lbs (183 N·m) torque for 2500/3500 single-rear wheel (SRW) models, and
140 ft lbs (190 N·m) for 3500 dual rear-wheel models. If in doubt about the
correct tightness, have them checked with a torque wrench by your authorized
dealer or at a service station.
• Install the wheel center cap and remove the wheel blocks. Do not install chrome or aluminum wheel center caps on the spare wheel. This may result in cap damage.
• Lower the jack to its fully closed position. If the bottle jack will not lower by turning the dial (thumbwheel) by hand, it may be necessary to use the jack drive
tube in order to lower the jack. Stow the replaced tire, jack, and tools as previously
described.
• Adjust the tire pressure when possible.
NOTE:
Do not oil wheel studs. For chrome wheels, do not substitute with chrome plated
wheel nuts.
WHAT TO DO IN EMERGENCIES
183
8-Stud — Dual Rear Wheels
• Dual wheels are flat-mounted and center-piloted. The lug nuts are a two-pieceassembly. When the tires are being rotated or replaced, clean these lug nuts and
add two drops of oil at the interface between the hex and the washer.
• Slots in the wheels will assist in prop- erly orienting the inner and outer
wheels. Align these slots when assem-
bling the wheels for best access to the
tire valve on the inner wheel. The tires
of both dual wheels must be com-
pletely off the ground when tightening,
to ensure wheel centering and maxi-
mum wheel clamping.
• Dual wheel models require a special heavy-duty lug nut tightening adapter
(included with the vehicle) to correctly
tighten the lug nuts. Also, when it is necessary to remove and install dual rear
wheels, use a proper vehicle lifting device.
NOTE:
When installing a spare tire as part of a dual rear wheel end combination, the tire
diameter of the two individual tires must be compared. If there is a significant
difference, the larger tire should be installed in a front location. The correct direction
of rotation for dual tire installations must also be observed.
These dual rear wheels should be tightened as follows:
1. Tighten the wheel nuts in the num- bered sequence to a snug fit.
2. Retighten the wheel nuts in the same sequence to the torques listed in the
table. Go through the sequence a
second time to verify that specific
torque has been achieved. Retighten to
specifications at 100 miles (160 km)
and after 500 miles (800 km).
• It is recommended that wheel stud
nuts be kept torqued to specifications
at all times. Torque wheel stud nuts to specifications at each lubrication interval.
WHAT TO DO IN EMERGENCIES
187
FLUIDS AND CAPACITIES
Gasoline Versions
ComponentFluid, Lubricant, or
Genuine Part Capacities
Engine Coolant
3.6L Engine We recommend you use
MOPAR
®Antifreeze/
Coolant 10 Year/150,000
Mile Formula OAT (Organic Additive Technology). 14 Quarts (13 Liters)
Engine Coolant
5.7L 1500 Models We recommend you use
MOPAR
®Antifreeze/
Coolant 10 Year/150,000
Mile Formula OAT (Organic Additive Technology). 16 Quarts (15 Liters)
Engine Coolant
5.7L 2500/3500 Models We recommend you use
MOPAR
®Antifreeze/
Coolant 10 Year/150,000
Mile Formula OAT (Organic Additive Technology) . 18.7 Quarts (17.7 Liters)
Engine Coolant
5.7L 2500/3500 Models
w/Heavy Duty We recommend you use
MOPAR
®Antifreeze/
Coolant 10 Year/150,000
Mile Formula OAT (Organic Additive Technology) . 19.2 Quarts (18.2 Liters)
Engine Coolant
6.4L 2500/3500 Models We recommend you use
MOPAR
®Antifreeze/
Coolant 10 Year/150,000
Mile Formula OAT (Organic Additive Technology) . 18.7 Quarts (17.7 Liters)
Engine Coolant
6.4L 2500/3500 Models
w/Heavy Duty We recommend you use
MOPAR
®Antifreeze/
Coolant 10 Year/150,000
Mile Formula OAT (Organic Additive Technology) . 19.2 Quarts (18.2 Liters)
Engine Oil with Filter
3.6L, 5.7L We recommend you use
API Certified SAE 5W-20 Engine Oil, meeting the
requirements of Chrysler Material Standard
MS-6395 such as
MOPAR
®, Pennzoil®,and
Shell Helix®. Refer to your
engine oil filler cap for correct SAE grade. 3.6L Engine - 6 Quarts
(5.7 Liters)
5.7L Engine - 7 Quarts (6.6 Liters)
MAINTAINING YOUR VEHICLE
205
ComponentFluid, Lubricant, or
Genuine Part Capacities
Engine Oil with Filter 5.7L
For 2500/3500 trucks
operating with a gross
combined weight rating
greater than 14,000 lbs/
(6,350 kg) We recommend you use
API Certified SAE 5W-30 Engine Oil, meeting the
requirements of Chrysler Material Standard
MS-6395 such as
MOPAR
®, Pennzoil®,and
Shell Helix®. Refer to your
engine oil filler cap for correct SAE grade. 5.7L Engine - 7 Quarts
(6.6 Liters)
Engine Oil with Filter 6.4L For best performance and
maximum protection under all types of operating con-ditions, the manufacturer
only recommends full syn-
thetic engine oils that meet the American Petroleum
Institute (API) categories of SN. The manufacturer recommends the use of
Pennzoil Ultra™ 0W-40 or
equivalent MOPAR
®engine
oil meeting the require-
ments of Chrysler Material Standard MS-12633 for use in all operating temperatures. 6.4L Engine - 7 Quarts
(6.6 Liters)
Engine Oil Filter
3.6L, 5.7L, 6.4L We recommend you
use MOPAR
®Engine
Oil Filters. —
Spark Plug 3.6L We recommend you use
MOPAR
®Spark Plugs
(Gap 0.043 in [1.1 mm]) —
Spark Plug 5.7L We recommend you use
MOPAR
®Spark Plugs
(Gap 0.043 in [1.1 mm]) —
Spark Plug 6.4L We recommend you use
MOPAR
®Spark Plugs
(Gap 0.043 in [1.1 mm]) —
MAINTAINING YOUR VEHICLE
206