8
ENHANCED ACCIDENT RESPONSE SYSTEM
(EARS) ................................................................ 371
EVENT DATA RECORDER (EDR) ....................... 371
BULB REPLACEMENT ........................................ 372 Replacement Bulbs ...................................372
Replacing Exterior Bulbs ...........................374
SERVICING AND MAINTENANCE
SCHEDULED SERVICING — GAS ENGINE ....... 380Maintenance Plan — Gasoline Engine......380
Heavy Duty Use Of The Vehicle ................. 384
SCHEDULED SERVICING— DIESEL ENGINE .... 384
Oil Change Indicator System — Cummins
Diesel ..........................................................385 Perform Service Indicator — Cummins
Diesel ..........................................................385
Maintenance Plan — Cummins Diesel
Engine ........................................................ 386
ENGINE COMPARTMENT .................................. 391
6.4L Engine ...............................................391
6.7L Diesel Engine — Six-Speed 68RFE ..392
6.7L Diesel Engine — Six-Speed
AS69RC HD ................................................393 Checking Oil Level — Gas Engine .............394
Checking Oil Level — Diesel Engine ..........394
Adding Washer Fluid..................................394
Maintenance-Free Battery .......................395
Pressure Washing ......................................395 DEALER SERVICE ..............................................396
Engine Oil .................................................. 396
Engine Oil Filter .......................................... 398
Engine Air Cleaner Filter............................ 398
Air Conditioner Maintenance .................... 400
Accessory Drive Belt Inspection ............... 403
Draining Fuel/Water Separator Filter —
Diesel Engine ............................................ 403 Engine Mounted Fuel Filter Replacement —
Diesel Engine ............................................. 405 Underbody Mounted Fuel Filter
Replacement — Diesel Engine .................. 406 Priming If The Engine Has Run Out Of
Fuel — Diesel Engine ................................. 407 Intervention Regeneration Strategy —
Message Process Flow ............................. 407 Diesel Exhaust Fluid .................................. 408
Body Lubrication ........................................ 408
Windshield Wiper Blades .......................... 409
Exhaust System ........................................ 410
Cooling System ......................................... 411
Charge Air Cooler — Inter-Cooler .............. 415
Brake System ............................................ 415
Automatic Transmission............................ 416
Rear Axle And 4x4 Front Driving Axle Fluid
Level .......................................................... 418 Transfer Case ............................................ 419
Noise Control System Required
Maintenance & Warranty ......................... 419 HOISTING ........................................................... 422
TIRES ................................................................... 422
Tire Safety Information.............................. 422
Tires — General Information .................... 428
Tire Types ................................................... 432
Spare Tires — If Equipped ......................... 433
Wheel And Wheel Trim Care ..................... 434
Tire Chains And Traction Devices ............ 435
Tire Rotation Recommendations ............. 436
DEPARTMENT OF TRANSPORTATION UNIFORM
TIRE QUALITY GRADES .................................... 438
Treadwear .................................................. 438
Traction Grades ......................................... 438
Temperature Grades ................................. 438
STORING THE VEHICLE ..................................... 439
BODYWORK ........................................................ 439
Protection From Atmospheric Agents....... 439
Body And Underbody Maintenance .......... 439
Preserving The Bodywork.......................... 440
INTERIORS ......................................................... 442
Seats And Fabric Parts .............................. 442
Plastic And Coated Parts........................... 442
Leather Parts ............................................. 443
Glass Surfaces .......................................... 443
20_DJD2_OM_EN_USC_t.book Page 8
228STARTING AND OPERATING
The block heater must be plugged in at least
one hour to have an adequate warming effect
on the coolant.
NOTE:
The block heater will require 110 Volts AC and
6.5 Amps to activate the heater element.
Block Heater Usage
For ambient temperatures below 0°F (-18°C),
engine block heater usage is recommended.
For ambient temperatures below –20°F
(-29°C), engine block heater usage is required.
ENGINE BREAK-IN RECOMMENDATIONS —
GAS ENGINE
A long break-in period is not required for the
engine and drivetrain (transmission and axle) in
your vehicle.
Drive moderately during the first 300 miles
(500 km). After the initial 60 miles (100 km), speeds up to 50 or 55 mph (80 or 90 km/h) are
desirable.
While cruising, brief full-throttle acceleration
within the limits of local traffic laws contributes
to a good break-in. Wide-open throttle accelera-
tion in low gear can be detrimental and should
be avoided.
The engine oil installed in the engine at the
factory is a high-quality energy conserving type
lubricant. Oil changes should be consistent with
anticipated climate conditions under which
vehicle operations will occur. For the recom
-
mended viscosity and quality grades, refer to
“Fluids And Lubricants” in “Technical Specifica-
tions”.
NOTE:
A new engine may consume some oil during its
first few thousand miles (kilometers) of opera -
tion. This should be considered a normal part of
the break-in and not interpreted as a problem.
Please check your oil level with the engine oil indicator often during the break in period. Add
oil as required.
ENGINE BREAK-IN RECOMMENDATIONS —
DIESEL ENGINE
The Cummins® Turbo Diesel engine does not
require a break-in period due to its construction.
Normal operation is allowed, providing the
following recommendations are followed:
Warm up the engine before placing it under
load.
Do not operate the engine at idle for
prolonged periods.
Use the appropriate transmission gear to
prevent engine lugging.
Observe vehicle oil pressure and tempera
-
ture indicators.
Check the coolant and oil levels frequently.
Vary throttle position at highway speeds
when carrying or towing significant weight.
WARNING!
Remember to disconnect the cord before
driving. Damage to the 110–115 Volt
electrical cord could cause electrocution.
CAUTION!
Never use Non-Detergent Oil or Straight
Mineral Oil in the engine or damage may
result.
20_DJD2_OM_EN_USC_t.book Page 228
312STARTING AND OPERATING
(Continued)
ENGINE RUNAWAY — DIESEL ENGINE
Diesel engine runaway is a rare condition
affecting diesel engines, where the engine
consumes its own lubrication oil and runs at
higher and higher RPM until it overspeeds to a
point where it destroys itself due to either
mechanical failure or engine seizure through
lack of lubrication.
REFUELING THE VEHICLE — GAS ENGINE
The fuel filler cap (gas cap) is located behind the
fuel filler door, on the left side of the vehicle.
Open the fuel door and remove the fuel filler cap
by turning it counter-clockwise.
Fuel Filler Cap
NOTE:
When removing the fuel filler cap, lay the cap
tether in the hook, located on the fuel filler door.
WARNING!
In case of engine runaway due to flammable
fumes from fuel spills or turbocharger oil
leaks being sucked into the engine, do the
following to help avoid personal injury and/or
vehicle damage:
1. Turn the ignition switch to the OFF position.
2. Using a CO2 or dry chemical type fire
extinguisher, direct the spray from the fire
extinguisher into the grille on the driver side
so that the spray enters the engine air intake.
The inlet for the engine air intake is located
behind the drivers side headlamp and
receives air through the grille.
WARNING!
Never have any smoking materials lit in or
near the vehicle when the gas cap is
removed or the tank is being filled.
Never add fuel to the vehicle when the
engine is running.
A fire may result if gasoline is pumped into
a portable container that is inside of a
vehicle. You could be burned. Always place
gas containers on the ground while filling.
CAUTION!
Damage to the fuel system or emissions
control system could result from using an
improper fuel tank filler tube cap.
A poorly fitting fuel filler cap could let impu -
rities into the fuel system.
A poorly fitting fuel filler cap may cause the
“Malfunction Indicator Light (MIL)” to turn
on.
To avoid fuel spillage and overfilling, do not
“top off” the fuel tank after filling. When the
fuel nozzle “clicks” or shuts off, the fuel
tank is full.
WARNING! (Continued)
20_DJD2_OM_EN_USC_t.book Page 312
336STARTING AND OPERATING
(Continued)
Off-Road Driving Tips
Care should be taken when attempting to climb
steep hills or driving diagonally across a hill or
slope. If natural obstacles force you to travel
diagonally up or down a hill, choose a mild angle
and keep as little side tilt as possible. Keep the
vehicle moving and make turns slowly and
cautiously. If you must back down a hill, back straight down
using REVERSE gear. Never back down in
NEUTRAL or diagonally across the hill.
When driving over sand, mud, and other soft
terrain, shift to low gear and drive steadily.
Apply the accelerator slowly to avoid spinning
the wheels.
Do not reduce the tire pressures for this type of
driving.
After Driving Off-Road
Off-road operation puts more stress on your
vehicle than does most on-road driving. After
going off-road, it is always a good idea to check
for damage. That way you can get any problems
taken care of right away and have your vehicle
ready when you need it.
Completely inspect the underbody of your
vehicle. Check tires, body structure, steering,
suspension, and exhaust system for damage.
Inspect the radiator for mud and debris and
clean as required.
Driving through standing water limits your
vehicle’s braking capabilities, which
increases stopping distances. Therefore,
after driving through standing water, drive
slowly and lightly press on the brake pedal
several times to dry the brakes.
Failure to follow these warnings may result
in injuries that are serious or fatal to you,
your passengers, and others around you.
CAUTION!
Always check the depth of the standing
water before driving through it. Never drive
through standing water that is deeper than
the bottom of the tire rims mounted on the
vehicle.
Determine the condition of the road or the
path that is under water and if there are any
obstacles in the way before driving through
the standing water.
Do not exceed 5 mph (8 km/h) when
driving through standing water. This will
minimize wave effects.
WARNING!
(Continued)
Driving through standing water may cause
damage to your vehicle’s drivetrain compo -
nents. Always inspect your vehicle’s fluids
(i.e., engine oil, transmission, axle, etc.) for
signs of contamination (i.e., fluid that is
milky or foamy in appearance) after driving
through standing water. Do not continue to
operate the vehicle if any fluid appears
contaminated, as this may result in further
damage. Such damage is not covered by
the New Vehicle Limited Warranty.
Getting water inside your vehicle’s engine
can cause it to lock up and stall out, and
cause serious internal damage to the
engine. Such damage is not covered by the
New Vehicle Limited Warranty.
CAUTION! (Continued)
20_DJD2_OM_EN_USC_t.book Page 336
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
380
SERVICING AND MAINTENANCE
SCHEDULED SERVICING — GAS ENGINE
Your vehicle is equipped with an automatic oil
change indicator system. The oil change indi-
cator system will remind you that it is time to
take your vehicle in for scheduled maintenance.
Based on engine operation conditions, the oil
change indicator message will illuminate. This
means that service is required for your vehicle.
Operating conditions such as frequent
short-trips, trailer tow, extremely hot or cold
ambient temperatures, and E85 fuel usage will
influence when the “Oil Change Required”
message is displayed. Severe Operating Condi-
tions can cause the change oil message to illu -
minate as early as 3,500 miles (5,600 km)
since last reset. Have your vehicle serviced as
soon as possible, within the next 500 miles
(805 km).
Your authorized dealer will reset the oil change
indicator message after completing the sched -
uled oil change.
If a scheduled oil change is performed by
someone other than your authorized dealer, the
message can be reset by referring to the steps described under “Instrument Cluster Display” in
“Getting To Know Your Instrument Panel”.
NOTE:
Under no circumstances should oil change
intervals exceed 8,000 miles (13,000 km),
12 months or 350 hours of engine run time,
whichever comes first. The 350 hours of engine
run or idle time is generally only a concern for
fleet customers.
Severe Duty All Models
NOTE:
Change Engine Oil at 4,000 miles (6,500 km) or
350 hours of engine run time if the vehicle is
operated in a dusty and off road environment or
is operated predominantly at idle, or only very
low engine RPM. This type of vehicle use is
considered Severe Duty.
Once A Month Or Before A Long Trip:
Check engine oil level
Check windshield washer fluid level
Check tire pressure and look for unusual
wear or damage. Rotate tires at the first sign
of irregular wear, even if it occurs before the
oil indicator system turns on.
Check the fluid levels of the coolant reservoir,
brake master cylinder, power steering and
automatic transmission (six-speed only) and
fill as needed
Check function of all interior and exterior
lights
Maintenance Plan — Gasoline Engine
Required Maintenance
Refer to the Maintenance Plan on the following
pages for required maintenance. More frequent
maintenance may be needed in severe condi
-
tions, such as dusty areas and very short trip
driving. In some extreme conditions, additional
maintenance not specified in the maintenance
schedule may be required.
20_DJD2_OM_EN_USC_t.book Page 380
384SERVICING AND MAINTENANCE
Heavy Duty Use Of The Vehicle
Change engine oil at 4,000 miles (6,500 km) or
350 hours of engine run time if the vehicle is
operated in a dusty and off road environment or
is operated predominately at idle or only very
low engine RPM. This type of vehicle use is
considered Severe Duty.
SCHEDULED SERVICING— DIESEL ENGINE
Required Maintenance Intervals
Refer to the maintenance plan on the following
pages for the required maintenance intervals.
More frequent maintenance may be needed in
severe conditions, such as dusty areas and very
short trip driving. In some extreme conditions,
additional maintenance not specified in the
maintenance schedule may be required.
At Each Stop For Fuel
Check the engine oil level at least 30 minutes
after a fully warmed engine is shut off. Checking
the oil level while the vehicle is on level ground
will improve the accuracy of the oil level
reading. Add oil only when the level is at or
below the ADD or MIN mark. Once A Month
Inspect the batteries, and clean and tighten
the terminals as required.
Check the fluid levels of the coolant reservoir,
brake master cylinder, and automatic trans-
mission, and add as needed.
At Each Oil Change
Change the engine oil filter.
Inspect the exhaust system.
Inspect engine air filter. Replace the engine
air filter cleaner, if necessary.
Inspect the CV/Universal joints.
Check the coolant level, hoses, and clamps.
Inspect front end, and lubricate — If equipped
with serviceable fittings.
Inspect and replace the Evaporative System
Fresh Air Filter as necessary, replacement
may be more frequent if vehicle is operated
in extreme dusty conditions.
WARNING!
You can be badly injured working on or
around a motor vehicle. Do only service
work for which you have the knowledge and
the right equipment. If you have any doubt
about your ability to perform a service job,
take your vehicle to a competent mechanic.
Failure to properly inspect and maintain
your vehicle could result in a component
malfunction and effect vehicle handling
and performance. This could cause an acci -
dent.
CAUTION!
Failure to perform the required maintenance
items may result in damage to the vehicle.
20_DJD2_OM_EN_USC_t.book Page 384