374IN CASE OF EMERGENCY
Replacing Exterior Bulbs
Base Quad: Low Beam Headlamp, High
Beam Headlamp, Front Park And Turn — If
Equipped
Low Beam
1. Open the hood.
2. Disconnect and isolate the negative battery
cable.
3. Reach into the front wheel house ahead of the front wheel, remove the fastener, and
lift the cover over the access hole in the
front of the wheel house splash shield.
Access to the rear of the lamp can be gained
through this access hole.
Splash Shield Access Cover
4. Reach through the access hole of the wheel house splash shield and disengage the bulb
access cover by rotating counterclockwise.
Bulb Access Cover
5. Disconnect the internal lamp wiring harness
connector from the low beam bulb.
6. Rotate the bulb counterclockwise a quarter turn to unlock the bulb from the lamp.
7. Pull the bulb straight out from the housing.
8. Reverse the procedure for installation of new bulb and covers.
High Beam
1. Open the hood.
2. Disconnect and isolate the negative battery cable.
1 — Access Cover
2 — Fastener
CAUTION!
Do not contaminate the bulb glass by
touching it with your fingers or by allowing it
to contact other oily surfaces. Shortened
bulb life will result.
Always use the correct bulb size and type
for replacement. An incorrect bulb size or
type may overheat and cause damage to
the lamp, the bulb socket, or the lamp
wiring.
20_DJD2_OM_EN_USC_t.book Page 374
IN CASE OF EMERGENCY375
3. Look under the hood and behind the head -
lamp to find the high beam bulb access
cover.
4. Reach behind the headlamp and disengage the access cover by rotating counterclock -
wise.
5. Disconnect the internal lamp wiring harness connector from the high beam bulb.
6. Rotate the bulb counterclockwise a quarter turn to unlock the bulb from the lamp.
7. Pull the bulb straight out from the housing.
8. Reverse the procedure for installation of new bulb and covers. Front Park And Turn
1. Open the hood.
2. Disconnect and isolate the negative battery
cable.
3. Look under the hood and behind the head -
lamp to find the park and turn socket.
Park And Turn Socket
4. Reach behind the headlamp and unlock the park and turn socket from the lamp by
rotating counterclockwise a quarter turn.
5. Pull the bulb straight out from the housing.
6. Separate the bulb from the socket without twisting. 7. Reverse the procedure for installation of
new bulb and covers.
Side Marker Lamp
1. Open the hood.
2. Disconnect and isolate the negative battery cable.
3. Reach into the front wheel house ahead of the front wheel, remove the fastener, and
lift the cover over the access hole in the
front of the wheel house splash shield.
Access to the rear of the lamp can be gained
through this access hole.
Splash Shield Access Cover
CAUTION!
Do not contaminate the bulb glass by
touching it with your fingers or by allowing it
to contact other oily surfaces. Shortened
bulb life will result.
Always use the correct bulb size and type
for replacement. An incorrect bulb size or
type may overheat and cause damage to
the lamp, the bulb socket, or the lamp
wiring.
1 — Access Cover
2 — Fastener
6
20_DJD2_OM_EN_USC_t.book Page 375
376IN CASE OF EMERGENCY
4. Reach through the access hole of the wheel
house splash shield and disengage the side
marker socket by rotating counterclockwise
a quarter turn.
Side Marker Socket
5. Pull the socket and bulb straight out from the housing.
6. Separate the bulb from the socket without twisting.
7. Reverse the procedure for installation of new bulb and covers.Fog Lamps — If Equipped
1. Reach under and behind the front bumper to access the back of the front fog lamp
housing.
2. Disconnect the fog lamp wiring harness connector from the fog lamp bulb.
3. Rotate the bulb counterclockwise a quarter turn to unlock the bulb from the housing.
4. Pull the bulb straight out from the housing.
Rear Tail/Stop, Turn Signal And Backup
Lamps
1. Remove the two screws and push pins that pass through the bed sheet metal.
Tail Lamp Locations
CAUTION!
Do not contaminate the bulb glass by
touching it with your fingers or by allowing it
to contact other oily surfaces. Shortened bulb
life will result.
1 — Tail Lamp
2 — Fasteners
20_DJD2_OM_EN_USC_t.book Page 376
IN CASE OF EMERGENCY377
2. Pull the outboard side of the lamp rearward
far enough to unsnap the two receptacles
on the outboard side of the lamp housing
from the two plastic snap post retainers in
the outer box side panel.
Tail Lamp Removed
3. Disconnect the wiring harness connectors from the bulb socket.
4. Rotate the bulb socket counterclockwise a quarter turn to unlock it from the housing.
5. Pull the bulb straight out of the socket. 6. Reverse the procedure to install the bulb
and housing.
Center High Mounted Stop Lamp (CHMSL)
With Cargo Lamp
1. Remove the two screws holding the housing/lens to the body as shown.
CHMSL Mounting Screw Locations
2. Separate the connector holding the housing and wiring harness to the body.
CHMSL Connector Location
3. Turn the desired bulb socket a quarter turn and remove the socket and bulb from
housing.
4. Pull the desired bulb straight from the socket.
CHMSL Bulb And Socket
1 — Tail Lamp Housing
2 — Bulb Socket Locations
CAUTION!
Do not contaminate the bulb glass by
touching it with your fingers or by allowing it
to contact other oily surfaces. Shortened bulb
life will result.
6
20_DJD2_OM_EN_USC_t.book Page 377
378IN CASE OF EMERGENCY
Outside Bulbs: Cargo Lamps
Inside Bulb: Center High Mounted Stop
Lamp
5. Reverse the procedure for installation of bulbs and housing.
Cab Top Clearance Lamps — If Equipped
1. Remove the screws from the top of the lamp.
Removing Rear Screw From Clearance Lamp
2. Rotate the bulb socket a quarter turn and
pull it from the lamp assembly.
Removing Bulb Socket From Clearance Lamp
3. Pull the bulb straight from it's socket and replace.
Removing The Bulb From The Bulb Socket
Rear Lamp Bar ID Marker (Dual Rear Wheels)
— If Equipped
1. Loosen the two screws and the housing to gain access to the bulb sockets.
Screw Locations
2. Turn the socket a quarter turn counterclock -
wise to access the bulb.
3. Pull the bulb straight out from the socket.
4. Reverse the procedure for installation of the bulbs and housing.
CAUTION!
Do not contaminate the bulb glass by
touching it with your fingers or by allowing it
to contact other oily surfaces. Shortened bulb
life will result.
20_DJD2_OM_EN_USC_t.book Page 378
IN CASE OF EMERGENCY379
Side Marker Lamps (Dual Rear Wheels) — If
Equipped
Side Marker Lamp Locations
1. Push rearward on the side marker lamp
assembly.
2. Pull the entire assembly from the fender.
3. Turn the socket a quarter turn counterclock -
wise and remove from assembly to access
the bulb. 4. Pull the bulb straight out from socket.
5. Reverse the procedure for installation of the
bulbs and housing.
6
20_DJD2_OM_EN_USC_t.book Page 379
404SERVICING AND MAINTENANCE
If water is detected in the water separator while
the engine is running, or while the ignition
switch is in the ON position, the “Water In Fuel
Indicator Light” will illuminate and an audible
chime will be heard five times. At this point you
should stop the engine and drain the water from
both of the filters.
If the “Water In Fuel Indicator Light” comes on
and a single chime is heard while you are
driving, or with the ignition switch in the ON
position, there may be a problem with your
water separator wiring or sensor. See an autho -
rized dealer for service.
Upon proper draining of the water from both
fuel filters, the “Water In Fuel Indicator Light”
will remain illuminated for approximately 10
seconds. If the water was drained while the
engine was running, the “Water In Fuel Indicator
Light” may remain on for approximately three
minutes. NOTE:
Care should be taken in disposing of used fluids
from your vehicle. Used fluids, indiscriminately
discarded, can present a problem to the envi
-
ronment. Contact an authorized dealer, service
station, or government agency for advice on
recycling programs and for where used fluids
and filters can be properly disposed of in your
area.
Drain the fuel/water separator filters when the
“Water In Fuel Indicator Light” is ON. Within
10 minutes of vehicle shutdown, turn the
engine mounted filter drain valve (located on
the side of the filter assembly) counterclock -
wise 1/4 turn, and turn the under body
mounted filter drain valve (located on the
bottom of the filter assembly) counterclockwise
wise 1 full turn. Then turn the ignition switch to
the ON position, and allow any accumulated
water to drain. Leave the drain valve open until
all water and contaminants have been
removed. When clean fuel is visible, close the
drain valve following these guidelines:
1. Rotate the drain clockwise to close until
you feel resistance from the internal seal.
2. Continue turning the drain 1/2 of a turn to properly compress the seal.
NOTE:
Over-compression of the seal due to over-tight -
ening of the drain will damage the seal, cause a
leak, and require the entire sensor to be
replaced.
3. Turn the ignition switch to OFF.
The sensor drain should not be over-tightened
during normal service operations to avoid
internal damage and future fuel leaks. The
drain should be closed and secured without the
use of tools.
If more than a couple ounces/milliliters of fuel
have been drained, follow the directions for
“Priming If The Engine Has Run Out Of Fuel.”
CAUTION!
If the “Water In Fuel Indicator Light” remains
on, DO NOT START the engine before you
drain water from the fuel filters to avoid
engine damage.
20_DJD2_OM_EN_USC_t.book Page 404
SERVICING AND MAINTENANCE405
Engine Mounted Fuel Filter Replacement —
Diesel Engine
NOTE:
Using a fuel filter that does not meet the
manufacturer's filtration and water sepa -
rating requirements can severely impact fuel
system life and reliability.
The engine mounted filter housing is
equipped with a No-Filter-No-Run (NFNR)
feature. Engine will not run if:
a. No filter is installed.
b. Inferior/Non-approved filter is used. Use of OEM filter is required to ensure vehicle
will run.
Engine Mounted Fuel Filter Assembly
1. Ensure engine is turned off.
2. Place drain pan under the fuel filter drain
hose.
3. Open the water drain valve a quarter turn counterclockwise and completely drain fuel
and water into the approved container.
4. Close the water drain valve.
5. Remove lid using a socket or strap wrench. Rotate counterclockwise for removal.
Remove used o-ring and discard it.
6. Remove the used filter cartridge from the housing and dispose of according to your
local regulations.
7. Wipe clean the sealing surfaces of the lid and housing.
8. Install new o-ring back into ring groove on the filter housing and lubricate with clean
engine oil.
9. Remove new filter cartridge from plastic bag and install into housing.
NOTE:
Do not remove cartridge from bag until you
reach this step in order to keep cartridge clean.
1 — Drain Valve
CAUTION!
Diesel fuel will damage blacktop paving
surfaces. Drain the filter into an appro-
priate container.
Do not prefill the fuel filter when installing a
new fuel filter. There is a possibility debris
could be introduced into the fuel filter
during this action. It is best to install the
filter dry and allow the in-tank lift pump to
prime the fuel system.
7
20_DJD2_OM_EN_USC_t.book Page 405