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NOTE:Ensure funnel is inserted fully to hold flapper
door open.
3. Pour fuel into funnel opening.
4. Remove funnel from filler pipe, clean off prior to
putting back in the jack kit.
CAUTION!
To avoid fuel spillage and overfilling, do not “top
off” the fuel tank after filling.
WARNING!
•Never have any smoking materials lit in or near the
vehicle when the fuel door is open or the tank is
being filled.
•Never add fuel when the engine is running. This is
in violation of most state and federal fire regula-
tions and may cause the “Malfunction Indicator
Light” to turn on.
•A fire may result if fuel is pumped into a portable
container that is inside of a vehicle. You could be
burned. Always place fuel containers on the
ground while filling.
Emergency Fuel Fill Location
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ADDING FUEL — CHASSIS CAB MODELS
CAUTION!
To avoid fuel spillage and overfilling, do not “top
off” the fuel tank after filling.
NOTE:
•When the fuel nozzle “clicks” or shuts off, the fuel tank
is full.
•Tighten the fuel filler cap until you hear a “clicking”
sound. This is an indication that the fuel filler cap is
properly tightened.
•Make sure that the fuel filler cap is tightened each time
the vehicle is refueled.
WARNING!
A fire may result if fuel is pumped into a portable
container that is on a truck bed. You could be burned.
Always place fuel containers on the ground while
filling.
Fuel Filler Cap
If the fuel filler cap is lost or damaged, be sure the
replacement cap is for use with this vehicle.
CAUTION!
Damage to the fuel system or emission control sys-
tem could result from using an improper fuel tank
filler tube cap. A poorly fitting cap could let impuri-
ties into the fuel system.
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WARNING!
•Never have any smoking materials lit in or near the
vehicle when the fuel filler cap is removed or the
tank filled.
•Never add fuel to the vehicle when the engine is
running.
Avoid Using Contaminated Fuel
Fuel that is contaminated by water or dirt can cause
severe damage to the engine fuel system. Proper main-
tenance of the engine fuel filter and fuel tank is essential.
Refer to “Maintenance Procedures” in “Maintaining Your
Vehicle” for further information.
Bulk Fuel Storage — Diesel Fuel
If you store quantities of fuel, good maintenance of the
stored fuel is also essential. Fuel contaminated with
water will promote the growth of “microbes.” Thesemicrobes form “slime” that will clog the fuel filtration
system and lines. Drain condensation from the supply
tank and change the line filter on a regular basis.
NOTE:When a diesel engine is allowed to run out of
fuel, air is pulled into the fuel system.
If the vehicle will not start, refer to “Maintenance
Procedures/Priming If The Engine Has Run Out Of Fuel”
in “Maintaining Your Vehicle” for further information.
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.
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Diesel Exhaust Fluid Storage
Diesel Exhaust Fluid (DEF) is considered a very stable
product with a long shelf life. If DEF is kept in tempera-
tures between 10° and 90°F (-12° and 32°C), it will last a
minimum of one year.
DEF is subject to freezing at the lowest temperatures. For
example, DEF may freeze at temperatures at or below 12°
F (-11° C). The system has been designed to operate in
this environment.
NOTE:When working with DEF, it is important to know
that:
•Any containers or parts that come into contact with
DEF must be DEF compatible (plastic or stainless
steel). Copper, brass, aluminum, iron or non-stainless
steel should be avoided as they are subject to corrosion
by DEF.
•If DEF is spilled, it should be wiped up completely.
Adding Diesel Exhaust Fluid
The DEF gauge (located on the instrument cluster) will
display the level of DEF remaining in the tank. Refer to
“Instrument Cluster” and “Instrument Cluster Descrip-
tions” in “Understanding Your Instrument Panel” for
further information.
NOTE:Driving conditions (altitude, vehicle speed, load,
etc.) will effect the amount of DEF that is used in your
vehicle.
DEF Fill Procedure
NOTE:Refer to “Fluids, Lubricants, and Genuine Parts”
in “Maintaining Your Vehicle” for the correct fluid type.
1. Remove cap from DEF tank (located on drivers side of
the vehicle or in fuel door).
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1 — Diesel Exhaust Fluid Fill Location
2 — Diesel Fuel Fill Location
2. Insert DEF fill adapter/nozzle into DEF tank filler
neck.
DEF Filler Cap Chassis Cab ModelsDEF Filler Cap And Fuel Fill 1500/2500/3500 Models
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CAUTION!
•To avoid DEF spillage, and possible damage to the
DEF tank from overfilling, do not “top off” the DEF
tank after filling.
(Continued)
CAUTION!(Continued)
•DO NOT OVERFILL. DEF will freeze below 12ºF
(-11ºC). The DEF system is designed to work in
temperatures below the DEF freezing point, how-
ever, if the tank is overfilled and freezes, the
system could be damaged.
•When DEF is spilled, clean the area immediately
with water and use an absorbent material to soak
up the spills on the ground.
•Do not attempt to start your engine if DEF is
accidentally added to the diesel fuel tank as it can
result in severe damage to your engine, including
but not limited to failure of the fuel pump and
injectors.
Filling The DEF Tank
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3. Stop filling the DEF tank immediately when any of the
following happen: DEF stops flowing from the fill
bottle into the DEF tank, DEF splashes out the filler
neck, or a DEF pump nozzle automatically shuts off.
4. Reinstall cap onto DEF tank.
Filling The Def Tank In Cold Climates
Since DEF will begin to freeze at 12°F (-11°C), your vehicle
is equipped with an automatic DEF heating system. This
allows the DEF injection system to operate properly at
temperatures below 12°F (-11°C). If your vehicle is not in
operation for an extended period of time with tempera-
tures below 12°F (-11°C), the DEF in the tank may freeze. If
the tank is overfilled and freezes, it could be damaged.
Therefore, do not overfill the DEF tank.
Extra care should be taken when filling with portable
containers to avoid overfilling. Note the level of the DEF
gauge in your instrument cluster. On pickup applications,you may safely add a maximum of 2 gallons of DEF from
portable containers when your DEF gauge is reading ½ full.
On Chassis Cab applications a maximum of 2 gallons may
be added when the DEF gauge is reading ¾ full.
TRAILER TOWING
In this section you will find safety tips and information
on limits to the type of towing you can reasonably do
with your vehicle. Before towing a trailer, carefully
review this information to tow your load as efficiently
and safely as possible.
To maintain the New Vehicle Limited Warranty coverage,
follow the requirements and recommendations in this
manual concerning vehicles used for trailer towing.
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Common Towing Definitions
The following trailer towing related definitions will assist
you in understanding the following information:
Gross Vehicle Weight Rating (GVWR)
The GVWR is the total allowable weight of your vehicle.
This includes driver, passengers, cargo and tongue
weight. The total load must be limited so that you do not
exceed the GVWR. Refer to “Vehicle Loading/Vehicle
Certification Label” in “Starting and Operating” for
further information.
Gross Trailer Weight (GTW)
The GTW is the weight of the trailer plus the weight of all
cargo, consumables and equipment (permanent or tem-
porary) loaded in or on the trailer in itsloaded and
ready for operationcondition. The recommended way tomeasure GTW is to put your fully loaded trailer on a
vehicle scale. The entire weight of the trailer must be
supported by the scale.
Gross Combination Weight Rating (GCWR)
The GCWR is the total permissible weight of your vehicle
and trailer when weighed in combination.
Gross Axle Weight Rating (GAWR)
The GAWR is the maximum capacity of the front and rear
axles. Distribute the load over the front and rear axles
evenly. Make sure that you do not exceed either front or
rear GAWR. Refer to “Vehicle Loading/Vehicle Certifica-
tion Label” in “Starting and Operating” for further
information.
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