RAM 2500 Diesel (2007 year). Instruction — part 26
MAINTAINING YOUR VEHICLE
CONTENTS
䡵 Engine Compartment — 6.7L Diesel Engine . . . . 408
䡵 Engine Compartment — 5.9L Diesel Engine . . . . 409
䡵 Onboard Diagnostic System (OBD II) . . . . . . . . . 410
䡵 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . 410
䡵 Engine Data Plate . . . . . . . . . . . . . . . . . . . . . . 411
䡵 Dealer Service . . . . . . . . . . . . . . . . . . . . . . . . . 411
䡵 Service Information . . . . . . . . . . . . . . . . . . . . . 411
䡵 Maintenance Procedures . . . . . . . . . . . . . . . . . . 414
▫ Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . 414
▫ Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
▫ Engine Air Cleaner Filter
(5.9L Diesel Engine) . . . . . . . . . . . . . . . . . . . 422
(6.7L Diesel Engines) . . . . . . . . . . . . . . . . . . . 424
▫ Draining Fuel/Water Separator Filter
(5.9L Diesel Engine) . . . . . . . . . . . . . . . . . . . 427
▫ Draining Fuel/Water Separator Filter
(6.7L Diesel Engine) . . . . . . . . . . . . . . . . . . . 430
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▫ Intervention Regeneration Strategy – EVIC
Message Process Flow (Catalyst Full Message)
(6.7L Diesel Engines Only) . . . . . . . . . . . . . . . 434
▫ Maintenance Free Batteries . . . . . . . . . . . . . . . 437
▫ Air Conditioner Maintenance . . . . . . . . . . . . . 438
▫ Power Steering — Fluid Check . . . . . . . . . . . . 439
▫ Front Suspension Ball Joints . . . . . . . . . . . . . . 440
▫ Steering Linkage — Inspection . . . . . . . . . . . . 440
▫ Front Prop Shaft Lubrication . . . . . . . . . . . . . 441
▫ Front Axle Universal Drive Joints And Pivot
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441
▫ Body Lubrication . . . . . . . . . . . . . . . . . . . . . 441
▫ Windshield Wiper Blades . . . . . . . . . . . . . . . . 442
▫ Windshield Washers . . . . . . . . . . . . . . . . . . . 442
▫ Exhaust System . . . . . . . . . . . . . . . . . . . . . . 443
▫ Cooling System . . . . . . . . . . . . . . . . . . . . . . . 444
▫ Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450
▫ Charge Air Cooler (Inter-Cooler) . . . . . . . . . . 450
▫ Hoses And Vacuum/Vapor Harnesses . . . . . . . 451
▫ Brake System . . . . . . . . . . . . . . . . . . . . . . . . 451
▫ Clutch Linkage . . . . . . . . . . . . . . . . . . . . . . . 453
▫ Clutch Hydraulic System . . . . . . . . . . . . . . . . 453
▫ Rear Axle And 4X4 Front Driving Axle
Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . 454
▫ Transfer Case — If Equipped . . . . . . . . . . . . . 455
▫ Instruction Transmission — If Equipped . . . . . . . 455
▫ Automatic Transmission . . . . . . . . . . . . . . . . 455
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▫ Front Wheel Bearings . . . . . . . . . . . . . . . . . . 458
▫ Noise Control System Required Maintenance &
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . 458
▫ Appearance Care And Protection From
Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . 463
䡵 Fuses (Integrated Power Module) . . . . . . . . . . . 468
䡵 Vehicle Storage . . . . . . . . . . . . . . . . . . . . . . . . 472
䡵 Replacement Light Bulbs . . . . . . . . . . . . . . . . . 473
䡵 Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . 474
▫ Headlight (Halogen)/Front Park And
Turn Lights . . . . . . . . . . . . . . . . . . . . . . . . . 474
▫ Fog Lights . . . . . . . . . . . . . . . . . . . . . . . . . . 477
▫ Tail, Stop, Turn And Backup Lights . . . . . . . . . 478
▫ Center High-Mounted Stoplight (CHMSL)
With Cargo Light . . . . . . . . . . . . . . . . . . . . . 481
▫ Cab Top Clearance Lights — If Equipped . . . . 482
▫ Tailgate ID Lights (Dual Rear Wheels) —
If Equipped . . . . . . . . . . . . . . . . . . . . . . . . . 484
▫ Rear Light Bar ID Marker (Dual Rear Wheel)
— If Equipped . . . . . . . . . . . . . . . . . . . . . . . 485
▫ Side Marker Lights (Dual Rear Wheels) . . . . . . 486
䡵 Fluid Capacities . . . . . . . . . . . . . . . . . . . . . . . . 487
䡵 Fluids, Lubricants And Genuine Parts . . . . . . . . 488
▫ Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 488
▫ Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . 491
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ENGINE COMPARTMENT — 6.7L DIESEL ENGINE
408
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ENGINE COMPARTMENT — 5.9L DIESEL ENGINE
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409
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ONBOARD DIAGNOSTIC SYSTEM (OBD II)
Vehicles equipped with California emissions controls
have a sophisticated onboard diagnostic system called
OBDII. This system monitors the performance of the
emissions, engine, and automatic transmission control
systems. When these systems are operating properly,
your vehicle will provide excellent performance and fuel
economy, as well as engine emissions well within current
government regulations.
If any of these systems require service, the OBD II system
will turn on the “Malfunction Indicator Light.” It will
also store diagnostic codes and other information to
assist your service technician in making repairs. Al-
though your vehicle will usually be driveable and not
need towing, see your dealer for service as soon as
possible.
CAUTION!
Prolonged driving with the “Malfunction Indicator
Light” on could cause further damage to the emission
control system. It could also affect fuel economy and
driveability. The vehicle must be serviced before any
emissions tests can be performed.
If the “Malfunction Indicator Light” is flashing,
severe catalytic converter damage and power loss
will soon occur. Immediate service is required.
REPLACEMENT PARTS
Use of genuine Mopar
威 parts for normal/scheduled
maintenance and repairs is highly recommended to in-
sure the designed performance. Damage or failures
caused by the use of non-Mopar parts for maintenance
and repairs will not be covered by the manufacturer’s
warranty.
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ENGINE DATA PLATE
Use the information from the engine data plate when
discussing service or sourcing parts for your engine. The
engine data plate is located on the intake side of the
breather cover.
DEALER SERVICE
Your dealer has the qualified service personnel, special
tools and equipment to perform all service operations in
an expert manner. Service instructions are available which
include detailed service information for your vehicle.
Refer to these instructions before attempting any procedure
yourself.
NOTE:
Intentional tampering with emissions control
systems can result in civil penalties being assessed
against you.
WARNING!
You can be badly injured working on or around a
motor vehicle. Do only that service work for which you
have the knowledge and the proper equipment. If you
have any doubt about your ability to perform a service
job, take your vehicle to a competent mechanic.
SERVICE INFORMATION
Mopar Fluids, Lubricants and Parts are available from
your dealer and will help you keep your vehicle operat-
ing at its best. Your dealer also has the qualified service
personnel, special tools and equipment to perform all
service operations in an expert manner. Service instructions
are available which include detailed service information
for your vehicle. Refer to these instructions before attempt-
ing any procedure yourself. See Service Publications
information at the back of this manual.
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CAUTION!
To maintain your vehicle safely follow these
guidelines:
• Watch your vehicle’s mileage and check your Mainte-
nance Schedules
regularly for required servicing. Ex-
cessive wear or damage to certain vehicle components
can result if required services are not performed.
• If you have your vehicle undercoated, inspect for
undercoating material on the propeller shafts. Such
material could cause the shafts to become unbalanced
and result in drivetrain vibrations. Remove any under-
coating with solvent.
• If you have your vehicle undercoated, make sure no
undercoating material is sprayed on the exhaust sys-
tem or components of the seat belt system.
NOTE:
It is not possible for the manufacturer and
Cummins, Inc. to anticipate every possible circumstance
that can involve a potential hazard.
WARNING!
To maintain your vehicle safely and avoid personal
injury, follow these guidelines:
• Never spray or pour diesel fuel, flammable liquid or
starting fluids (ether) into the air cleaner assembly, air
intake piping or turbocharger inlet in an attempt to
start the vehicle, unintended engine acceleration may
occur.
• 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.
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• If an engine has been operating and the coolant is hot,
allow the engine to cool before you slowly loosen the
filler cap and relieve the pressure from the cooling
system.
• To avoid burns, remember that the engine components
will stay hot after the engine is shut off.
• Do not use gasoline or other flammable materials to
clean parts. Always use approved cleaning solvents.
• Relieve all pressure in the fuel, oil and cooling systems
before any lines, fittings or related items are removed
or disconnected. Be alert for possible pressure when
disconnecting any device from a system that utilizes
pressure. Do not check for pressure leaks with your
hand. High pressure oil or fuel can cause personal
injury.
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.
• Important: All maintenance other than that listed in
this instruction, as well as some procedures listed here,
MUST
be performed by your local Dodge Truck
Dealer. Your authorized Dodge Dealer has been
trained and has the necessary parts to maintain your
engine.
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MAINTENANCE PROCEDURES
The pages that follow contain the required maintenance
services determined by the engineers who designed your
vehicle.
Besides the maintenance items for which there are fixed
maintenance intervals, there are other items that should
operate satisfactorily without periodic maintenance.
However, if a malfunction of these items does occur, it
could adversely affect the engine or vehicle performance.
These items should be inspected if a malfunction is
observed or suspected.
Engine Oil
Checking Oil Level
To assure proper lubrication of your vehicle’s engine, the
engine oil must be maintained at the correct level. Check
the oil level at regular intervals. The best time to check
the oil level is before starting the engine after it has been
parked overnight. When checking oil after operating the
engine, first ensure the engine is at full operating tem-
perature, then wait at least 30 minutes after engine
shutdown to check the oil.
Checking the vehicle while it’s on level ground will also
improve the accuracy of the oil level readings. Add oil
only when the level on the dipstick is below the “ADD”
mark. The total capacity from the low mark to the high
mark is 2 quarts (1.9 liters).
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CAUTION!
Overfilling or underfilling the crankcase will cause
oil aeration or loss of oil pressure. This could damage
your engine.
Never operate the engine with oil level below the “ADD”
mark or above the upper “SAFE” mark.
Change Engine Oil (5.9L Diesel Engine)
Road conditions as well as your kind of driving affect the
interval at which your oil should be changed. Check the
following to determine if any apply to you:
• Frequent short trips where the engine does not achieve
full operating temperature (operating temperature de-
fined as 190° F (66° C ) coolant temperature).
• Extensive engine idling (over 10 minutes per hour of
operation) at ambient temperatures less than 32° F (0°
C).
• Driving in dusty conditions.
• Frequent trailer towing.
• Taxi, police, or delivery service (commercial service).
• Off-road or desert operation.
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• Extensive operation at high engine speeds (greater
than 2900 rpm) and loads (greater than 70% throttle).
If ANY of these apply to you, then change your engine oil
at every interval shown in schedule
⬙B⬙ of the ⬙Mainte-
nance Schedules
⬙ section of this instruction.
If none of these apply to you, then change your engine oil
at every interval shown on schedule
⬙A⬙ of the ⬙Mainte-
nance Schedules
⬙ section of this instruction.
NOTE:
Most vehicles are operated under the conditions
listed for Schedule
⬙B.⬙
Change Engine Oil (6.7L Diesel Engine)
Follow the 6.7L Diesel Maintenance Schedule for recom-
mended engine oil change intervals.
Engine Oil Selection (5.9L Diesel Engine)
1. Engine Oil Quality
Use only oils conforming to API Ser-
vice CI-4. A sulfated ash limit is speci-
fied for lubrication oil used in Cum-
mins engines. Oils with a high ash
content may produce deposits on
valves that can progress to guttering
and valve burning. A maximum sul-
fated ash content of 1.85 mass % is recommended for all
oil used in the engine.
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2. Engine Oil Viscosity (SAE Grade)
The proper SAE viscosity of engine oil for the expected
ambient temperature range should be selected, as indi-
cated in the following chart:
NOTE:
The same oil change interval is to be followed
for synthetic oil as for petroleum based oil. Also, syn-
thetic oil must meet the same performance specifications
as petroleum oil.
You may use synthetic engine oils provided the recom-
mended oil quality requirements are met, and the recom-
mended maintenance intervals for oil and filter changes
are followed.
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Engine Oil Selection (6.7L Diesel Engines)
For best performance and maximum protection under all
types of operating conditions, the manufacture only
recommends engine oils that are API CJ-4 certified and
meet the requirements of DaimlerChrysler. Use Mopar or
an equivalent oil meeting the specification MS-10902.
Products meeting Cummins CES 20081 may also be used.
The identification of these engine oils are typically lo-
cated on the back of the oil container.
American Petroleum Institute (API) Engine Oil
Identification Symbol
This symbol means that the oil has
been certified by the American Petro-
leum Institute (API). The manufacture
only recommends API Certified en-
gine oils.
Oils with a high ash content may produce deposits on
valves that can progress to guttering and valve burning.
A maximum sulfated ash content of 1.00 mass % is
recommended for all oil used in the engine.
The same oil change interval is to be followed for
synthetic oil as for petroleum based oil. Also, synthetic oil
must meet the same performance specifications as petro-
leum oil.
Engine Oil Viscosity (SAE Grade)
Use
SAE
15W-40
Engine
Oil
that
meets
DaimlerChrysler Materials Standard MS-10902 and the
API CJ-4 engine oil category.
Engine oil not designated by the DaimlerChrysler or
Cummins Material Standards and API CJ-4 should not be
used, engine and exhaust system durability may be
compromised. For lower temperature operation SAE
5W-40 engine oils may be used. These oils must meet the
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same requirements as stated previously. Your engine oil
filler cap also shows the recommended engine oil viscos-
ity for your vehicle.
Synthetic Engine Oils
You may use synthetic engine oils provided the recom-
mended oil quality requirements are met, and the recom-
mended maintenance intervals for oil and filter changes
are followed.
Materials Added to Engine Oil
The manufacture strongly recommends against the addi-
tion of any additives (other than leak detection dyes or
lube odorants) to the engine oil. Engine oil is an engi-
neered product and it’s performance may be impaired by
supplemental additives.
NOTE:
The manufacturer offers a lube odorant (Mopar
Diesel Fresh) for diesel engines crankcases. The lube
odorant is recommended by the manufacturer to reduce
the sulfur smell that may occur during engine idling.
Engine Oil Filter
Refer to Fluids, Lubricants and Genuine Parts for the
correct part number. The engine oil filter should be
changed at every engine oil change.
Engine Oil And Filter — Change
Operate the engine until the coolant temperature reaches
140°F (60°C). Shut the engine off. Remove the oil drain
plug.
Use a container that can hold at least 12 quarts (11.3
Liters) to hold the used oil.
Always check the condition of the used oil. This can give
you an indication of some engine problems that might
exist.
• Thin, black oil indicates fuel dilution.
• Milky discoloration indicates coolant dilution.
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Clean the area around the oil filter base. Remove the filter
from the underside of the vehicle using a cap style oil
filter wrench.
Clean the gasket surface of the filter mount. The filter
gasket can stick on the filter mount. Make sure it is
removed.
Change the engine oil filter with every engine oil change.
Only a high quality MOPAR filter should be used to
assure most efficient service.
CAUTION!
The filtering medium of other aftermarket filters
may disintegrate. Debris from failed filters may plug
the piston oil cooling nozzles, resulting in scuffed
pistons and engine failure.
CAUTION!
Fill the oil filter element with clean oil before instal-
lation. Use the same type oil that will be used in the
engine. When filling the oil filter, prevent foreign
material from falling into the filter. Severe engine
damage may occur.
Apply a light film of lubricating oil to the sealing surface
of the filter gasket before installing the filter.
CAUTION!
Overtightening may distort the threads or damage
the filter element seal.
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