SERVICING AND MAINTENANCE399
Engine Air Cleaner Filter Removal
1. With suitable tool fully loosen (six)
fasteners on air cleaner filter.
Air Cleaner Filter
2. Lift the air cleaner cover to access the air cleaner filter.
3. Remove the air cleaner filter element from the housing assembly.
Open Air Cleaner Filter Assembly
Engine Air Cleaner Filter Installation
NOTE:
Inspect and clean the housing if dirt or debris is
present before replacing the air filter element.
1. Install the air cleaner filter element into the housing assembly with the air cleaner filter
inspection surface facing downward.
2. Install the air cleaner cover onto the housing assembly.
3. Tighten the fasteners (six) on the air cleaner filter assemblyEngine Air Cleaner Filter Inspection and
Replacement — Diesel Engine
Inspect engine air cleaner filter for dirt and or
debris, if you find evidence of either dirt or
debris you should change your air cleaner filter.
Engine Air Cleaner Filter Removal
1. Remove the screws from the air cleaner cover.
Air Cleaner Filter Cover
2. Lift the air cleaner cover to access the air cleaner filter.
1 — Fasteners
2 — Air Hose Clamp
3 — Air Cleaner Cover
1 — Air Cleaner Cover
2 — Air Cleaner Filter
1 — Air Cleaner Filter Cover
2 — Screws
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400SERVICING AND MAINTENANCE
3. Remove the air cleaner filter element from
the housing assembly.
Air Cleaner Filter
Engine Air Cleaner Filter Installation
NOTE:
Inspect and clean the housing if dirt or debris is
present before replacing the air filter element.
1. Install the air cleaner filter element into the housing assembly with the air cleaner filter
inspection surface facing downward.
2. Install the air cleaner cover onto the housing assembly locating tabs. 3. Install screws to secure the air cleaner
cover to the housing assembly.
Air Conditioner Maintenance
For best possible performance, your air condi -
tioner 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.
Refrigerant Recovery And Recycling —
R-134a — (If Equipped)
R-134a Air Conditioning Refrigerant is a hydro -
fluorocarbon (HFC) that is an ozone-friendly
substance. The manufacturer recommends
that air conditioning service be performed by an
authorized dealer or other service facilities
using recovery and recycling equipment.
NOTE:
Use only manufacturer approved A/C system
PAG compressor oil and refrigerants.
Refrigerant Recovery And Recycling —
R-1234yf — (If Equipped)
R–1234yf Air Conditioning Refrigerant is a
hydrofluoroolefin (HFO) that is endorsed by the
Environmental Protection Agency and is an
ozone-friendly substance with a low
global-warming potential. The manufacturer
1 — Air Cleaner Filter
2 — Air Cleaner Filter Inspection Surface
WARNING!
Use only refrigerants and compressor lubri -
cants approved by the manufacturer for
your air conditioning system. Some unap -
proved refrigerants are flammable and can
explode, injuring you. Other unapproved
refrigerants or lubricants can cause the
system to fail, requiring costly repairs.
Refer to Warranty Information Book, for
further warranty information.
The air conditioning system contains refrig -
erant 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 technician.
CAUTION!
Do not use chemical flushes in your air
conditioning system as the chemicals can
damage your air conditioning components.
Such damage is not covered by the New
Vehicle Limited Warranty.
20_DJD2_OM_EN_USC_t.book Page 400
SERVICING AND MAINTENANCE401
recommends that air conditioning service be
performed by an authorized dealer using
recovery and recycling equipment.
NOTE:
Use only manufacturer approved A/C system
PAG compressor oil, and refrigerants.
Cabin Filter Replacement (A/C Air Filter)
Refer to the “Maintenance Plan” for the proper
maintenance intervals.
The cabin air filter is located in the fresh air inlet
behind the glove compartment. Perform the
following procedure to replace the filter:
1. Open the glove compartment and remove
all contents.
2. With the glove compartment door open, remove the glove compartment tension
tether and tether clip by sliding the clip
toward the face of the glove compartment
door. Lift the clip out of glove compartment
door and release into dash panel.
Right Side Of Glove Compartment
3. There are travel stops on both sides of the
glove compartment. Push inward on right
side of the glove compartment travel stop to
disengage the stop. Then pull the right of
the glove compartment outward (away from
the hinge) to disengaging the right side of
the compartment from the hinge. Continue
by removing the left side from the hinge by
slightly lowering the compartment while
pulling outward until it is completely disen -
gaged from the hinge.
Glove Compartment
WARNING!
Do not remove the cabin air filter while the
vehicle is running, or while the ignition is in
the ACC or ON/RUN mode. With the cabin air
filter removed and the blower operating, the
blower can contact hands and may propel dirt
and debris into your eyes, resulting in
personal injury.
1 — Glove Compartment Door
2 — Glove Compartment Tension Tether
1 — Glove Compartment Travel Stop
2 — Glove Compartment Tension Tether
3 — Glove Compartment Door
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402SERVICING AND MAINTENANCE
4. Remove the filter cover by pushing in on the
finger tabs on each end of the filter cover.
Filter Cover
Filter Cover Removal
5. Remove the cabin air filter by pulling it
straight out of the housing.
Cabin Air Filter
6. Install the cabin air filter with the arrow on the filter pointing toward the floor. When
installing the filter cover, press on each end
until you hear an audible click.
7. Reinstall the glove compartment on the hinges. 8. Pull the tension tether outward and reinstall
the glove compartment past the travel stops
by pushing in on the glove compartment
sides.
Right Side Of Glove Compartment
NOTE:
Ensure the glove compartment door hinges and
glove compartment travel stops are fully
engaged.
9. Reattach the glove compartment tension tether by inserting the tether clip in the
glove compartment and sliding the clip
away from the face of the glove compart -
ment door.
1 — Finger Tabs
CAUTION!
The cabin air filter is identified with an arrow
to indicate airflow direction through the filter.
Failure to properly install the filter will result
in the need to replace it more often.
1 — Glove Compartment Travel Stop
2 — Glove Compartment Tension Tether
3 — Glove Compartment Door
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SERVICING AND MAINTENANCE407
Priming If The Engine Has Run Out Of Fuel —
Diesel Engine
1. Add a substantial amount of fuel to the
tank, approximately 2 to 5 gal (8L to 19L).
2. Three priming cycles must be completed. Turn ignition to the RUN position and wait
approximately 30 seconds. This will activate
the in tank fuel pump. Turn the ignition
switch to the off position, and leave off for at
least 30 seconds. Repeat this procedure
three times before cranking the engine.
3. Start the engine using the “Normal Starting” procedure. Refer to “Starting Procedures”
in “Starting and Operating” for further infor -
mation.
4. Once the engine starts, allow the engine to idle for a minimum of 30 seconds. NOTE:
The engine may run rough until the air is forced
from all the fuel lines.
NOTE:
A maximum blend of 5% biodiesel, meeting
ASTM specification D-975 may be used with
your Cummins diesel engine. (Chassis Cab
models not configured with B20 capability.)
A maximum blend of 20% biodiesel, meeting
ASTM specification D-7467 may be used with
your Cummins diesel engine. (Pickup models
and Chassis Cab models configured with B20
capability.)
Use of biodiesel mixture in excess of 20% can
negatively impact the fuel filter's ability to
separate water from the fuel, resulting in
high pressure fuel system corrosion or
damage.
Ethanol blends are not recommended or
approved for use with your Cummins diesel
engine.
In addition, commercially available fuel addi
-
tives are not necessary for the proper opera -
tion of your Cummins diesel engine.
Intervention Regeneration Strategy —
Message Process Flow
The Cummins diesel engine meets all Environ -
mental Protection Agency (EPA) Heavy Duty
Diesel Engine Emissions Standards, resulting in
one of the lowest emitting diesel engines ever
produced.
To achieve these emissions standards, your
vehicle is equipped with a state-of-the-art
engine and exhaust system. The engine and
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.
CAUTION!
Do not engage the starter motor for more
than 15 seconds at a time. Allow two minutes
between the cranking intervals.
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.
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416SERVICING AND MAINTENANCE
Automatic Transmission
Selection Of Lubricant
It is important to use the proper transmission
fluid to ensure optimum transmission perfor-
mance and life. Use only the manufacturer’s
specified transmission fluid. Refer to “Fluids
And Lubricants” in “Technical Specifications”. It
is important to maintain the transmission fluid
at the correct level using the recommended
fluid. No chemical flushes should be used in any
transmission; only the approved lubricant
should be used.
Special Additives
The manufacturer strongly recommends
against using any special additives in the trans -
mission. Automatic Transmission Fluid (ATF) is an engineered product and its performance
may be impaired by supplemental additives.
Therefore, do not add any fluid additives to the
transmission. The only exception to this policy is
the use of special dyes for diagnosing fluid
leaks in six-speed transmissions. Avoid using
transmission sealers as they may adversely
affect seals.
Fluid Level Check — Eight-Speed
Transmission
The fluid level is preset at the factory and does
not require adjustment under normal operating
conditions. Routine fluid level checks are not
required, therefore the transmission has no
dipstick. An authorized dealer can check your
transmission fluid level using special service
tools.
If you notice fluid leakage or transmission
malfunction, visit an authorized dealer immedi
-
ately to have the transmission fluid level
To avoid contamination from foreign matter
or moisture, use only new brake fluid or
fluid that has been in a tightly closed
container. Keep the master cylinder reser -
voir cap secured at all times. Brake fluid in
a open container absorbs moisture from
the air resulting in a lower boiling point. This
may cause it to boil unexpectedly during
hard or prolonged braking, resulting in
sudden brake failure. This could result in a
collision.
Overfilling the brake fluid reservoir can
result in spilling brake fluid on hot engine
parts, causing the brake fluid to catch fire.
Brake fluid can also damage painted and
vinyl surfaces, care should be taken to
avoid its contact with these surfaces.
Do not allow petroleum based fluid to
contaminate the brake fluid. Brake seal
components could be damaged, causing
partial or complete brake failure. This could
result in a collision.
WARNING! (Continued)
CAUTION!
Using a transmission fluid other than the
manufacturer’s recommended fluid may
cause deterioration in transmission shift
quality and/or torque converter shudder, and
(for six-speed transmissions) will require
more frequent fluid and filter changes. Refer
to “Fluids And Lubricants” in “Technical
Specifications” for fluid specifications.
CAUTION!
Do not use chemical flushes in your
transmission as the chemicals can damage
your transmission components. Such damage
is not covered by the New Vehicle Limited
Warranty.
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420SERVICING AND MAINTENANCE
The air filter element must also be clean and
serviced according to the instructions outlined
in the Scheduled Maintenance section of this
manual.
Tampering With Noise Control System
Prohibited
Federal law prohibits the following acts or the
causing thereof: (1) the removal or rendering
inoperative by any person, other than for
purposes of maintenance, repair, or replace -
ment, of any device or element of design incor -
porated into any new vehicle for the purpose of
noise control prior to its sale or delivery to the
ultimate purchaser or while it is in use, or (2) the
use of the vehicle after such device or element
of design has been removed or rendered inop -
erative by any person.
Among those acts presumed to constitute
tampering are the acts listed below. AIR CLEANER
Removal of the air cleaner.
Removal of the air cleaner filter element from
the air cleaner housing.
Removal of the air ducting.
EXHAUST SYSTEM
Removal or rendering inoperative exhaust
system components including the muffler or
tailpipe.
ENGINE COOLING SYSTEM
Removal or rendering inoperative the fan
clutch.
Removal of the fan shroud.
Noise Emission Warranty
The manufacturer warrants that this vehicle as
manufactured by the manufacturer, was
designed, built and equipped to conform at the
time it left the manufacturer's control with all
applicable U.S. EPA Noise Control Regulations.
This warranty covers this vehicle as designed,
built and equipped by the manufacturer, and is
not limited to any particular part, component or
system of the vehicle manufactured by the
manufacturer. Defects in design, assembly or in
any part, component or system of the vehicle as
manufactured by the manufacturer, which, at
the time it left the manufacturer's control,
caused noise emissions to exceed Federal stan -
dards, are covered by this warranty for the life of
the vehicle.
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448TECHNICAL SPECIFICATIONS
NOTE:
Intentional tampering with the emissions
control system can result in civil penalties being
assessed against you.
Carbon Monoxide Warnings
FUEL REQUIREMENTS – DIESEL ENGINE
Use good quality diesel fuel from a reputable
supplier in your vehicle. Federal law requires
that you must fuel this vehicle with Ultra Low
Sulfur Highway Diesel fuel (15 ppm Sulfur
maximum) and prohibits the use of Low Sulfur
Highway Diesel fuel (500 ppm Sulfur maximum)
to avoid damage to the emissions control
system.
For most year-round service, No. 2 diesel fuel
meeting ASTM (formerly known as the American
Society for Testing and Materials) specification
D-975 Grade S15 will provide good perfor -
mance. If the vehicle is exposed to extreme cold
(below 20°F or -7°C), or is required to operate
at colder-than-normal conditions for prolonged
periods, use climatized No. 2 diesel fuel or
dilute the No. 2 diesel fuel with 50% No. 1 diesel
fuel. This will provide better protection from fuel
gelling or wax-plugging of the fuel filters. Diesel fuel is seldom completely free of water.
To prevent fuel system trouble, drain the accu
-
mulated water from the fuel/water separator
using the fuel/water separator drain provided
on both fuel filters. If you buy good quality fuel
and follow the cold weather advice above, fuel
conditioners should not be required in your
vehicle. If available in your area, a high cetane
“premium” diesel fuel may offer improved
cold-starting and warm-up performance.
Fuel Specifications
The Cummins® Turbo Diesel engine has been
developed to take advantage of the high energy
content and generally lower cost No. 2 Ultra Low
Sulfur diesel fuel or No. 2 Ultra Low Sulfur clima-
tized diesel fuels. Experience has shown that it
also operates on No. 1 Ultra Low Sulfur diesel
fuels or other fuels within specification.
WARNING!
Carbon monoxide (CO) in exhaust gases is
deadly. Follow the precautions below to
prevent carbon monoxide poisoning:
Do not inhale exhaust gases. They contain
carbon monoxide, a colorless and odorless
gas, which can kill. Never run the engine in
a closed area, such as a garage, and never
sit in a parked vehicle with the engine
running for an extended period. If the
vehicle is stopped in an open area with the
engine running for more than a short
period, adjust the ventilation system to
force fresh, outside air into the vehicle.
Guard against carbon monoxide with
proper maintenance. Have the exhaust
system inspected every time the vehicle is
raised. Have any abnormal conditions
repaired promptly. Until repaired, drive with
all side windows fully open.WARNING!
Do not use alcohol or gasoline as a fuel
blending agent. They can be unstable under
certain conditions and hazardous or
explosive when mixed with diesel fuel.
CAUTION!
If the “Water in Fuel Indicator Light” remains
on, DO NOT START engine before you drain
the water from the fuel filter(s) to avoid
engine damage. Refer to “Draining Fuel/
Water Separator Filter” in “Servicing And
Maintenance” for further information.
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