332SERVICING AND MAINTENANCE
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 transmis -
sion, and add as needed. At Each Oil Change
Change the engine oil filter.
Inspect the exhaust system.
Check the tire inflation pressures and look for
unusual wear or damage. Rotate at the first sign
of irregular wear.
Inspect engine air cleaner filter. Replace the
engine air cleaner filter, 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.
Inspection and service should also be performed
anytime a malfunction is observed or suspected.
Retain all receipts.
NOTE:Using white lithium grease, lubricate the door
hinge pivot joints twice a year to prevent
premature wear.
OIL CHANGE INDICATOR SYSTEM —
D
IESEL ENGINE
Your vehicle is equipped with an engine oil change
indicator system. This system will alert you when it
is time to change your engine oil by displaying the
words “Oil Change Due” in your instrument cluster
display. The engine oil change indicator system is
duty cycle based, which means the engine oil
change interval may fluctuate depending on your
personal driving style. Failure to change the engine
oil per the maintenance schedule can result in
internal engine damage.
An authorized dealer will reset the oil change
indicator message after completing the scheduled
oil change. If a scheduled oil change is performed
by someone other than an authorized dealer, the
message can be reset by referring to the steps
described under Instrument Cluster Display
Ú page 81.
Replace the engine oil and oil filter every
15,000 miles (24,000 km) or 12 months, or
sooner if prompted by the oil change indicator
system. Under no circumstances should oil change
intervals exceed 15,000 miles (24,000 km) or 12 months, whichever comes first.CAUTION!
Failure to perform the required maintenance
items may result in damage to the vehicle.
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SERVICING AND MAINTENANCE333
NOTE:
Under no circumstances should oil change inter -
vals exceed 15,000 miles (24,000 km) or
12 months or 500 hours, whichever comes first.
It is recommended that every 3,000 miles
(4,800 km), 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.
Severe service (high ambient temperature,
short trips, heavy loading, trailer towing,
off-road, or law enforcement use) may reduce
oil change intervals. If models configured with optional B20 capability
are operated with greater than 5% levels of
biodiesel, the oil change interval must not exceed
12,500 miles (20,000 km) or 400 hours,
whichever comes first under any circumstances.
See the Fuel Requirements section for more
information regarding operation with biodiesel
blend (B6-B20) fuel meeting ASTM specification
D-7467.
PERFORM SERVICE INDICATOR —
D
IESEL ENGINE
Your vehicle will require emissions maintenance at
a set interval. To help remind you when this
maintenance is due, the instrument cluster will
display “Perform Service”. When the “Perform
Service” message is displayed on the instrument
cluster it is necessary to have the emissions
maintenance performed. Emissions maintenance
may include replacing the Closed Crankcase
Ventilation (CCV) filter element. The procedure for
clearing and resetting the “Perform Service”
indicator message is located in the appropriate
Service Information.
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SERVICING AND MAINTENANCE335
Inspect the front suspension, tie rod
ends and boot seals for cracks or leaks
and all parts for damage, wear,
improper looseness or end play;
replace if necessary. X X X X X X X X X
X
Inspect the brake linings. XXXXX X
Inspect and adjust parking brake. XXXXX X
Inspect drive belt; replace as
necessary. X
XXXX X
Inspect wheel bearings. XXXX X
Additional Maintenance
Replace the cabin air filter. To be replaced every 12,000 mi (19,000 km).
Replace the engine fuel filter. X X X X X X X X X X
Replace the chassis mounted fuel
filter. X X X X X X X X X
X
Mileage or time passed (whichever
comes first):
7,500
15,000
22,500
30,000
37,500
45,000
52,500
60,000
67,500
75,000
82,500
90,000
97,500
105,000
112,500
120,000
127,500
135,000
142,500
150,000
Or Months: 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120
Or Kilometers:
12,000
24,000
36,000
48,000
60,000
72,000
84,000
96,000
108,000
120,000
132,000
144,000
156,000
168,000
180,000
192,000
204,000
216,000
228,000
240,000
8
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340SERVICING AND MAINTENANCE
CHECKING OIL LEVEL
To ensure proper engine lubrication, the engine oil
must be maintained at the correct level. Check the
oil level at regular intervals, such as every fuel
stop. The best time to check the engine oil level is
about five minutes after a fully warmed up engine
is shut off.
Checking the oil while the vehicle is on level ground
will improve the accuracy of the oil level readings.
There are four possible dipstick types:
Crosshatched zone.
Crosshatched zone marked SAFE.
Crosshatched zone marked with MIN at the low
end of the range and MAX at the high end of the
range.
Crosshatched zone marked with dimples at the
MIN and the MAX ends of the range.
NOTE:Always maintain the oil level within the crosshatch
markings on the dipstick.
Adding 1 quart (1 liter) of oil when the reading is at
the low end of the dipstick range will raise the oil
level to the high end of the range marking.
ADDING WASHER FLUID
The fluid reservoir is located under the hood and
should be checked for fluid level at regular
intervals. Fill the reservoir with windshield washer
solvent only (not radiator antifreeze). When
refilling the washer fluid reservoir, take some
washer fluid and apply it to a cloth or towel and
wipe the wiper blades clean. This will help blade
performance.
To prevent freeze-up of your windshield washer
system in cold weather, select a solution or mixture
that meets or exceeds the temperature range of
your climate. This rating information can be found
on most washer fluid containers.
After the engine has warmed up, operate the
defroster for a few minutes to reduce the
possibility of smearing or freezing the fluid on the
cold windshield. Windshield washer solution used
with water as directed on the container, aids
cleaning action, reduces the freezing point to avoid
line clogging, and is not harmful to paint or trim.
MAINTENANCE-FREE BATTERY
Your vehicle is equipped with a maintenance-free
battery. You will never have to add water, and
periodic maintenance is not required.
NOTE:Replacement batteries should both be of equal
capacity to prevent damage to the vehicle's
charging system.
CAUTION!
Overfilling or underfilling the crankcase will
cause oil aeration or loss of oil pressure. This
could damage your engine.
WARNING!
Commercially available windshield washer
solvents are flammable. They could ignite and
burn you. Care must be exercised when filling or
working around the washer solution.
WARNING!
Battery fluid is a corrosive acid solution and
can burn or even blind you. Do not allow
battery fluid to contact your eyes, skin, or
clothing. Do not lean over a battery when
attaching clamps. If acid splashes in eyes or
on skin, flush the area immediately with large
amounts of water Úpage 320.
Battery gas is flammable and explosive. Keep
flame or sparks away from the battery. Do not
use a booster battery or any other booster
source with an output greater than 12 Volts.
Do not allow cable clamps to touch each
other.
Battery posts, terminals, and related accesso -
ries contain lead and lead compounds. Wash
hands after handling.
22_DPF_OM_EN_USC_t.book Page 340
SERVICING AND MAINTENANCE347
along a rib (not across) are not normal. Any belt
with cracks running along a rib must be replaced.
Also have the belt replaced if it has excessive wear,
frayed cords or severe glazing.
Accessory Belt (Serpentine Belt)
Conditions that would require replacement:
Rib chunking (one or more ribs has separated
from belt body)
Rib or belt wear
Longitudinal belt cracking (cracks between two
ribs)
Belt slips
“Groove jumping" (belt does not maintain
correct position on pulley)
Belt broken (note: identify and correct problem
before new belt is installed)
Noise (objectionable squeal, squeak, or rumble
is heard or felt while drive belt is in operation)
Some conditions can be caused by a faulty
component such as a belt pulley. Belt pulleys
should be carefully inspected for damage and
proper alignment.
Belt replacement on some models requires the
use of special tools, we recommend having your
vehicle serviced at an authorized dealer.
DRAINING FUEL/WATER SEPARATOR
F
ILTER
There are two fuel filter assemblies. One is located
on the driver's side of the engine. The best access
to this water drain valve is from under the hood.
The second one is on the under body, located in
front of the rear axle above the drive shaft on
pick-up models. The second filter location is on the
frame behind the front axle. The best access to this
water drain valve is from under the vehicle. 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 authorized 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
CAUTION!
Do not drain the fuel/water separator filter
when the engine is running.
Diesel fuel will damage blacktop paving
surfaces. Drain the filter into an appropriate
container.
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.
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348SERVICING AND MAINTENANCE
station, or government agency for advice on recy -
cling 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) counterclockwise a quarter
turn, and turn the under body mounted filter drain
valve (located on the bottom of the filter assembly)
counterclockwise 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 half of a turn to properly compress the seal.
NOTE:Over-compression of the seal due to overtightening
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 overtightened
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
Ú
page 350
ENGINE MOUNTED FUEL FILTER
R
EPLACEMENT
NOTE:
Using a fuel filter that does not meet the manu -
facturer's filtration and water separating
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:
No filter is installed.
Inferior/Non-approved filter is used. Use of
OEM filter is required to ensure vehicle will
run.
Engine Mounted Fuel Filter Assembly
1 — Drain Valve
CAUTION!
Diesel fuel will damage blacktop paving
surfaces. Drain the filter into an appropriate
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.
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SERVICING AND MAINTENANCE349
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.
10. Push down on the cartridge to ensure it is properly seated. Do not pre-fill the filter
housing with fuel. 11. Install lid onto housing and tighten to 22.5 ft lb
(30.5 N.m). Do not overtighten the lid.
12. Prime the engine, then start the engine and confirm there are no leaks Ú page 350.
UNDERBODY MOUNTED FUEL FILTER
R
EPLACEMENT
NOTE:
Using a fuel filter that does not meet the manu -
facturer's filtration and water separating
requirements can severely impact fuel system
life and reliability.
The underbody mounted filter housing will
cause the engine not to run if:
a. No filter is installed.
Underbody 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 one full 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.
1 — Drain Valve
CAUTION!
Diesel fuel will damage blacktop paving
surfaces. Drain the filter into an appropriate
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.
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350SERVICING AND MAINTENANCE
8. Install new o-ring back into ring groove on the filter housing and lubricate with clean engine
oil.
NOTE:Water In Fuel (WIF) sensor is re-usable. Service kit
comes with new o-ring for filter canister and WIF
sensor.
PRIMING IF THE ENGINE HAS RUN OUT
O
F FUEL
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 approxi -
mately 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 Ú page 108.
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.
A maximum blend of 20% biodiesel, meeting
ASTM specification D-7467 may be used with
your Cummins® diesel engine.
Use of biodiesel mixture in excess of 20% can
negatively impact the fuel filter's ability to sepa -
rate water from the fuel, resulting in high pres -
sure 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 operation
of your Cummins® diesel engine.
INTERVENTION REGENERATION
S
TRATEGY — MESSAGE PROCESS FLOW
The Cummins® diesel engine meets all
Environmental 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 exhaust
after-treatment system work together to achieve
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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