2016 Ram 1500 maintenance procedures

MAINTAINING YOUR VEHICLE
CONTENTS
ENGINE COMPARTMENT — 3.0L DIESEL .....90
 MAINTENANCE PROCEDURES ............91
▫ Engine Oil ...........................92
▫ Engine Air Cleaner Filter ................94
▫ Draining Fuel/Water Separator Filter ........97
▫ Underbody Mounted Fuel Filter Replacement. .100
▫ Priming If The Engine Has Run Out Of Fuel . .101
▫ Intervention Regeneration Strategy — Message
Process Flow ....................... .103▫
Maintenance-Free Batteries ..............103
▫ Cooling System ..................... .104
▫ Charge Air Cooler — Inter-Cooler .........110
▫ Brake System ........................110
 FLUID CAPACITIES ....................113

FLUIDS, LUBRICANTS AND GENUINE PARTS . . .114
▫ Engine .............................114
▫ Chassis ............................118
5

MAINTENANCE PROCEDURES
The pages that follow contain therequiredmaintenance
services determined by the engineers who designed your
vehicle.
Besides those maintenance items specified in the fixed
maintenance schedule, there are other components which
may require servicing or replacement in the future.
CAUTION!
• Failure to properly maintain your vehicle or per-
form repairs and service when necessary could
result in more costly repairs, damage to other
components or negatively impact vehicle perfor-
mance. Immediately have potential malfunctions
examined by an authorized dealership or qualified
repair center.
(Continued)
CAUTION! (Continued)
•Your vehicle has been built with improved fluids
that protect the performance and durability of your
vehicle and also allow extended maintenance inter-
vals. Do not use chemical flushes in these compo-
nents as the chemicals can damage your engine,
transmission, power steering or air conditioning.
Such damage is not covered by the New Vehicle
Limited Warranty. If a flush is needed because of
component malfunction, use only the specified
fluid for the flushing procedure.
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MAINTAINING YOUR VEHICLE 91

A MESSAGE FROM FCA US LLC
FCA US LLC and Cummins welcome 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 FCA US LLC, and
service and repair facilities, when servicing your vehicle.
This information may be used to determine if repair will
be covered by the New Vehicle Limited 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.
134 INTRODUCTION

Water in Fuel Indicator Light — If Equipped
Yellow TelltaleLight What It Means
Water in Fuel Indicator Light
The “Water In Fuel Indicator Light” will illuminate when there is water detected in the fuel
filters. If this light remains on, DO NOT start the vehicle before you drain the water from
the fuel filters to prevent engine damage. Refer to “Maintenance Procedures” in “Maintain-
ing Your Vehicle” for further information.
Low Diesel Exhaust Fluid (DEF) Indicator Light — If Equipped
Yellow Telltale
Light What It Means
Low Diesel Exhaust Fluid (DEF) Indicator Light
The Low Diesel Exhaust Fluid (DEF) Indicator will illuminate if the vehicle is low on Diesel
Exhaust Fluid (DEF). Refer to “Starting And Operating” for further information.
158 UNDERSTANDING YOUR INSTRUMENT PANEL

CAUTION!
If the “Water in Fuel Indicator Light” remains on, DO
NOT START engine before you drain the water from
the fuel filters to avoid engine damage. Refer to
“Maintenance Procedures/Draining Fuel/Water Sepa-
rator Filter” in “Maintaining Your Vehicle” for fur-
ther information.
4. After the engine “Wait To Start” telltale goes off, the engine will automatically crank.
CAUTION!
The engine may automatically crank when the “Wait
To Start” time has elapsed. To abort the automatic
starting process, ensure the driver ’s foot is fully
removed from the brake pedal prior to pushing the
START/STOP button to cycle the ignition off. 5. After engine start-up, check to see that there is oil
pressure.
6. Allow the engine to idle about three minutes until the manifold heaters have completed the post-heat cycle.
7. Release the parking brake and drive.
NOTE:
• Engine idle speed will automatically increase to
1,000 RPM and engage the Variable Geometry Turbo-
charger at low coolant temperatures to improve engine
warm-up.
• The engine may not automatically crank after the
engine Wait To Start telltale goes off if a door or the
hood is ajar.
• If the engine stalls, or if the ignition switch is left ON
for more than two minutes after the “Wait To Start
Light” goes out, reset the grid heaters by turning the
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STARTING AND OPERATING 201

3. Turn the ignition switch to the ON position and watchthe 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 filters 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.
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 that the oil pressure warning light has turned off.
7. Release the parking brake.
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STARTING AND OPERATING 203

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) or Driver Information
Display (DID) does not necessarily reflect the engine
manifold air temperature. Refer to “Electronic Vehicle
Information Center (EVIC)” or “Driver Information Dis-
play (DID)” in “Understanding Your Instrument Panel”
for further information. 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” telltale will remain on for a period of time that varies depending on the engine tempera-
ture. 2. While the
Wait To Start” telltale is on, the EVIC/DID
will additionally display a gauge or bar whose initial
length represents the full Wait To Starttime period.
Its length will decrease until it disappears when the
Wait To Start time has elapsed.
CAUTION!
If the “Water in Fuel Indicator Light” remains on, DO
NOT START engine before you drain the water from
the fuel filters to avoid engine damage. Refer to
“Maintenance Procedures/Draining Fuel/Water Sepa-
rator Filter” in “Maintaining Your Vehicle” for fur-
ther information.
3. After the “Wait To Start” telltale goes off, turn the ignition switch to the START position. Do not press the
accelerator during starting.
204 STARTING AND OPERATING

NOTE:
•Engine idle speed will automatically increase to
1,000 RPM and engage the Variable Geometry Turbo-
charger at low coolant temperatures to improve engine
warm-up.
• 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.
• If the engine stalls, or if the ignition switch is left ON
for more than two minutes after the “Wait To Start”
telltale goes out, reset the grid heaters by turning the
ignition switch to the OFF position for at least five
seconds and then back ON. Repeat steps 1 through 5 of
“Starting Procedure – Engine Manifold Air Tempera-
ture Below 66°F (19°C).”Starting Fluids
WARNING!
Starting fluids or flammable liquids must never be
used in the Cummins diesel 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.
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STARTING AND OPERATING 207