Dodge 2500 Diesel (2008 year). Manual — part 17

STARTING AND OPERATING

CONTENTS

m Starting Procedures – Diesel Engines . . . . . . . . . 268

▫ Automatic Transmission – If Equipped . . . . . . 268
▫ Manual Transmission – If Equipped . . . . . . . . 269
▫ Normal Starting Procedure – Engine Manifold

Air Temperature Above 66°F (19°C) . . . . . . . . 269

▫ Starting Procedure – Engine Manifold Air

Temperature Below 66°F (19°C) . . . . . . . . . . . 270

▫ Starting Fluids . . . . . . . . . . . . . . . . . . . . . . . 274

m Normal Operation (Diesel Engine) . . . . . . . . . . . 274

▫ Cold Weather Precautions . . . . . . . . . . . . . . . 275

▫ Engine Idling . . . . . . . . . . . . . . . . . . . . . . . . 278
▫ Stopping The Engine . . . . . . . . . . . . . . . . . . . 280
▫ Engine Speed Control . . . . . . . . . . . . . . . . . . 281
▫ Operating Precautions . . . . . . . . . . . . . . . . . . 281
▫ Cooling System Tips — Automatic

Transmission . . . . . . . . . . . . . . . . . . . . . . . . 281

m Diesel Exhaust Brake (Engine Braking) –

If Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . . 283

m Transmission Shifting . . . . . . . . . . . . . . . . . . . . 285

▫ Automatic Transmission With Overdrive

(68RFE) — If Equipped . . . . . . . . . . . . . . . . . 285

5

m Manual Transmission . . . . . . . . . . . . . . . . . . . . 291

▫ Shifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
▫ Downshifting . . . . . . . . . . . . . . . . . . . . . . . . 293
▫ Reverse Shifting . . . . . . . . . . . . . . . . . . . . . . 294

m Four–Wheel Drive Operation — If Equipped . . . 294

▫ Manually Shifted Transfer Case Operating

Information/Precautions . . . . . . . . . . . . . . . . 294

▫ Shifting Procedure - Manually Shifted Transfer

Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297

▫ Transfer Case Reminder Light . . . . . . . . . . . . 298
▫ Electronically Shifted Transfer Case Operating

Information/Precautions (4 Position Switch) —
If Equipped . . . . . . . . . . . . . . . . . . . . . . . . . 299

▫ Shifting Procedure — Electronically Shifted

Transfer Case . . . . . . . . . . . . . . . . . . . . . . . . 303

m Limited-Slip Differential — If Equipped . . . . . . . 306
m Driving On Slippery Surfaces . . . . . . . . . . . . . . 307
m Driving Through Water . . . . . . . . . . . . . . . . . . 307

▫ Flowing/Rising Water . . . . . . . . . . . . . . . . . . 307
▫ Shallow Standing Water . . . . . . . . . . . . . . . . . 308

m Driving Off-Road . . . . . . . . . . . . . . . . . . . . . . . 309
m Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . 310
m Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . 312

▫ Brake Noise . . . . . . . . . . . . . . . . . . . . . . . . . 312
▫ Four-Wheel Anti-Lock Brake System . . . . . . . . 313

m Power Steering . . . . . . . . . . . . . . . . . . . . . . . . 315
m Tire Safety Information . . . . . . . . . . . . . . . . . . . 316

▫ Tire Markings . . . . . . . . . . . . . . . . . . . . . . . . 316

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▫ Tire Identification Number (TIN) . . . . . . . . . . 319
▫ Tire Loading And Tire Pressure . . . . . . . . . . . 320

m Tires — General Information . . . . . . . . . . . . . . . 324

▫ Tire Pressure . . . . . . . . . . . . . . . . . . . . . . . . . 324
▫ Tire Inflation Pressures . . . . . . . . . . . . . . . . . 325
▫ Radial Ply Tires . . . . . . . . . . . . . . . . . . . . . . 327
▫ Compact Spare Tire — If Equipped . . . . . . . . . 328
▫ Limited-Use Spare — If Equipped . . . . . . . . . 328
▫ Tire Spinning . . . . . . . . . . . . . . . . . . . . . . . . 329
▫ Tread Wear Indicators . . . . . . . . . . . . . . . . . . 330
▫ Life Of Tire . . . . . . . . . . . . . . . . . . . . . . . . . 330
▫ Replacement Tires . . . . . . . . . . . . . . . . . . . . . 331
▫ Alignment And Balance . . . . . . . . . . . . . . . . . 332

m Supplemental Tire Pressure Information — If

Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333

m Tire Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
m Snow Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
m Tire Rotation Recommendations . . . . . . . . . . . . 335

▫ Dual Rear Wheels . . . . . . . . . . . . . . . . . . . . . 337

m Tire Pressure Monitor System (TPMS) —

If Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . . 338

▫ Tire Pressure Monitor System (TPMS) “Light

Load” Reset Switch Description –
If Equipped . . . . . . . . . . . . . . . . . . . . . . . . . 341

▫ Tire Pressure Monitor System Components . . . 344
▫ General Information . . . . . . . . . . . . . . . . . . . 347

m Engine Runaway . . . . . . . . . . . . . . . . . . . . . . . 347

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m Fuel Requirements . . . . . . . . . . . . . . . . . . . . . . 348

▫ Fuel Requirements (6.7L Diesel Engines) . . . . . 348

m Adding Fuel (Diesel Engines) . . . . . . . . . . . . . . 349

▫ Fuel Filler Cap (Gas Cap) . . . . . . . . . . . . . . . 350
▫ Bulk Fuel Storage . . . . . . . . . . . . . . . . . . . . . 351

m Vehicle Loading . . . . . . . . . . . . . . . . . . . . . . . . 352

▫ Certification Label . . . . . . . . . . . . . . . . . . . . . 352

m Trailer Towing . . . . . . . . . . . . . . . . . . . . . . . . . 356

▫ Common Towing Definitions . . . . . . . . . . . . . 356
▫ Trailer Hitch Classification . . . . . . . . . . . . . . . 360
▫ Trailer Towing Weights (Maximum Trailer

Weight Ratings) . . . . . . . . . . . . . . . . . . . . . . 361

▫ Trailer And Tongue Weight . . . . . . . . . . . . . . 361
▫ Towing Requirements . . . . . . . . . . . . . . . . . . 362
▫ Towing Tips . . . . . . . . . . . . . . . . . . . . . . . . . 368
▫ Trailer Towing Mirrors — If Equipped . . . . . . 370

m Snowplow . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371

▫ Before Plowing . . . . . . . . . . . . . . . . . . . . . . . 372
▫ Snowplow Prep Package Model Availability . . 372
▫ Over The Road Operation With Snowplow

Attached . . . . . . . . . . . . . . . . . . . . . . . . . . . 373

▫ Methods For Removing Snow . . . . . . . . . . . . 373
▫ Operating Tips . . . . . . . . . . . . . . . . . . . . . . . 373
▫ General Maintenance . . . . . . . . . . . . . . . . . . . 374

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m Recreational Towing (Behind Motorhome, Etc.) . . 375

▫ Recreational Towing – 2-Wheel Drive

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375

▫ Recreational Towing – 4-Wheel Drive

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375

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STARTING PROCEDURES – DIESEL ENGINES

Before starting your vehicle, adjust your seat, adjust both
inside and outside mirrors, and fasten your seat belts.

The starter should not be operated for more than 15-
second intervals. Waiting a few minutes between such
intervals will protect the starter from overheating.

WARNING!

Be sure to turn off the engine and remove the key
from the ignition switch if you want to rest or sleep
in your vehicle. Accidents can be caused by inadvert-
ently moving the shift lever or by pressing the
accelerator pedal. This may cause excessive heat in
the exhaust system, resulting in overheating and
vehicle fire which may cause serious or fatal injuries.

WARNING!

Do not leave children or animals inside parked
vehicles in hot weather. Interior heat build up may
cause serious injury or death.

Automatic Transmission – If Equipped

Start the engine with the shift lever in NEUTRAL or
PARK position. Apply the brake before shifting to any
driving range.

The Cummins

t Diesel engine is equipped with several

features designed to assist cold weather starting and
operation:

• The engine block heater is a resistance heater installed

in the water jacket of the engine just above and behind
the oil filter. It requires a 110–115 volt AC electrical
outlet with a grounded, three-wire extension cord.

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NOTE:

The engine block heater cord is a factory in-

stalled option. If your vehicle is not equipped, heater
cords are available from your authorized Mopar

t dealer.

• A 12–volt heater built into the fuel filter housing aids

in preventing fuel gelling. It is controlled by a built-in
thermostat.

• A heated intake air system both improves engine

starting and reduces the amount of white smoke
generated by a warming engine.

Manual Transmission – If Equipped

Apply the parking brake, place the shift lever in NEU-
TRAL and depress the clutch pedal to the floor before
starting the vehicle. This vehicle is equipped with a
clutch interlocking ignition system. It will not start unless
the clutch is fully depressed.

Normal Starting Procedure – Engine Manifold Air
Temperature Above 66°F (19°C)

Observe the instrument panel cluster lights when starting
the engine.

1. Always apply the parking brake.

2. Shift into PARK for an automatic transmission. For
vehicles equipped with manual transmissions, fully de-
press and hold the clutch pedal and shift into NEUTRAL.

3. Turn the ignition key to the ON position and watch the
instrument panel cluster lights.

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5

CAUTION!

If WATER IN FUEL indicator light remains on DO
NOT START engine before you drain water from the
fuel filter to avoid engine damage. Refer to “Drain-
ing Fuel/Water Separator Filter (6.7L Diesel Engine)”
under “Maintenance Procedures” in Section 7.

4. Turn the ignition key to START and crank the engine.
Do not press the accelerator during starting.

CAUTION!

Do not crank engine for more than 15 seconds at a
time as starter motor damage may result. Turn key to
OFF and wait at least two minutes before trying
again.

5. When the engine starts, release the key.

6. Check to see that there is oil pressure.

7. Release the parking brake.

Starting Procedure – Engine Manifold Air
Temperature Below 66°F (19°C)

NOTE:

The temperature displayed on the overhead

console (if equipped) does not necessarily reflect the
engine manifold air temperature. When certain engine
temperatures fall below 66°F (19°C) the lights will remain
on indicating the intake manifold heater system is active.

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Follow the steps in the Normal Starting Procedure ex-
cept:

CAUTION!

Do not crank engine for more than 15 seconds at a
time or starter motor damage may result. Turn key to
OFF and wait at least two minutes for starter to cool
before repeating start procedure.

• The WAIT TO START light will remain on for a period

of time (length of time depends on engine tempera-
ture).

• After the WAIT TO START light goes off, turn the

ignition key to START. Do not press the accelerator
during starting.

• After engine start-up, check to see that there is oil

pressure.

• Allow the engine to idle about three minutes until

the manifold heaters have completed the post-heat
cycle.

• Release the parking brake and drive.

NOTE:

Engine idle speed will automatically increase to

1000 RPM at low coolant temperatures to improve engine
warm-up.

NOTE:

If the engine stalls or if the ignition switch is left

ON for more than two minutes after the WAIT TO START
light goes out, reset the grid heaters by turning the
ignition switch to OFF for at least five seconds and then
back ON. Repeat steps 3 through 7 of the normal starting
procedure.

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5

For Extremely Cold Weather Starting — Engine
Manifold Air Temperature Below 0°F (-18°C)
In extremely cold weather below 0°F (-18°C) it may be
beneficial to cycle the manifold heaters twice before
attempting to start the engine. This can be accomplished
by turning the ignition OFF for at least five seconds and
then back ON after the WAIT TO START light has gone
off, but before the engine is started. However, repeated
cycling of the manifold heaters will result in damage to
the heater elements or reduced battery voltage.

Proceed by following the steps in the Normal Starting
Procedure.

NOTE:

If multiple pre-heat cycles are used before

starting, additional engine run time may be required to
maintain battery state of charge at a satisfactory level.

• If the engine stalls after the initial start, the ignition

must be turned to the OFF position for at least five
seconds and then to the ON position to recycle the
manifold heaters.

NOTE:

Excessive white smoke and poor engine perfor-

mance will result if manifold heaters are not recycled.

• Heat generated by the manifold heaters dissipates

rapidly in a cold engine. If more than two minutes
pass between the time the WAIT TO START light goes
OFF and the engine is started, recycle the manifold
heaters by turning the ignition OFF for at least five
seconds and then back ON.

• If the vehicle is driven and vehicle speed exceeds 19

mph (31 km/h) before the manifold heater post-heat
(after start) cycle is complete, the manifold heaters will
shut off.

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• If the engine is started before the WAIT TO START

light turns off, the preheat cycle will turn off.

• If the engine is cranked for more than 10 seconds, the

post-heat cycle will turn off.

NOTE:

Engine idle speed will automatically increase to

1000 RPM at low coolant temperatures to improve engine
warm-up.

NOTE:

When a diesel engine is allowed to run out of

fuel or the fuel gels at low temperatures, air is pulled into
the fuel system.

You may try priming as described below:

1. Add a substantial quantity of fuel to the tank (5 to 10
gal) (19 to 38 L) or eliminate the gelled fuel condition.

2. Crank the engine for one to two seconds. If the engine
does not start, then turn the ignition back to the RUN
position (do not turn the ignition back to the OFF

position). The electric fuel transfer pump will continue to
run and purge air from the system for about 20 seconds.
After 20 seconds, attempt to start the engine again.

3. Start the engine using the Normal Starting Procedure.

4. Repeat the procedure if the engine does not start.

WARNING!

Do not open the high pressure fuel system when
cranking the engine or with the engine running.
Engine operation causes high fuel pressure. High
pressure fuel spray can cause serious injury or death.

NOTE:

The engine may run rough until the air is forced

from all the fuel lines.

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Starting Fluids

WARNING!

STARTING FLUIDS or flammable liquids are
NEVER TO BE USED in the Cummins

t Diesel (see

Warning label). Never pour diesel fuel, flammable
liquid, starting fluids (ether) into the air cleaner
canister, air intake piping, or turbocharger inlet in an
attempt to start the vehicle. This could result in a
flash fire and explosion causing serious personal
injury and engine damage.

The engine is equipped with an automatic electric air
preheating system. If the instructions in this manual are
followed, the engine should start in all conditions.

WARNING!

Do not leave children or animals inside parked
vehicles in hot weather. Interior heat build up may
cause serious injury or death.

NORMAL OPERATION (DIESEL ENGINE)

Observe the following when the engine is operating.

• All message center lights are off.
• Check Engine Lamp is off.
• Engine Oil Pressure is above 10 psi (69 kPa) at idle.
• Low Oil Pressure light is off.

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• Voltmeter Operation:

1. The voltmeter may show a gauge fluctuation if
certain engine temperatures are below 66°F (19°C).
This cycling operation is caused by the post-heat cycle
of the intake manifold heater system. The number of
cycles and the length of the cycling operation is
controlled by the engine control module. Post-heat
operation can run for several minutes, and then the
electrical system and voltmeter needle will stabilize.

2. The cycling action will cause temporary dimming of
the headlamps, interior lamps, and also a noticeable
reduction in blower motor speed.

Cold Weather Precautions

Operation in ambient temperature below 32°F (0°C) may
require special considerations. The following charts sug-
gest these options:

Fuel Operating Range (6.7L Diesel Engine)

NOTE:

Use “Ultra Low Sulfur Diesel Fuels” ONLY.

*No. 1 Ultra Low Sulfur diesel fuel should only be used
where extended arctic conditions (-10°F/-23°C) exist.

NOTE:

• Use of Climatized Ultra Low Sulfur Diesel Fuel or

Number 1 Ultra Low Sulfur Diesel Fuel results in a
noticeable decrease in fuel economy.

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• Climatized Ultra Low Sulfur Diesel Fuel is a blend of

Number 2 Ultra Low Sulfur and Number 1 Ultra Low
Sulfur Diesel Fuels which reduces the temperature at
which wax crystals form in fuel.

NOTE:

The engine requires the use of “Ultra Low

Sulfur Diesel Fuel”

. Use of incorrect fuel could result in

engine and exhaust system damage. Refer to Fuel Re-
quirements in this section for further details on fuel
recommendations.

Engine Block Heater
The engine block heater warms engine coolant and
permits quicker starts in cold weather. Connect the heater
cord to a ground–fault interrupter protected 110–115 volt
AC electrical outlet with a grounded, three-wire exten-
sion cord.

The engine block heater cord is routed under the hood to
the right side and can be located just behind the grille
near the headlamp.

NOTE:

The engine block heater cord is a factory in-

stalled option. If your vehicle is not equipped, heater
cords are available from your authorized Mopar

t dealer.

The block heater must be plugged in at least one hour to
have an adequate warming effect on the coolant.

WARNING!

Remember to disconnect the cord before driving.
Damage to the 110–115 volt electrical cord could
cause electrocution.

NOTE:

The block heater will require 110 Volts AC and

6.5 Amps to activate the heater element.

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Block Heater Usage

A. Temperatures below 0°F (-18°C)

• Block Heater Required for 15W-40
• Block Heater Recommended for 5W-40

B. Temperatures below - 20°F (-29°C)

• Block Heater Required for 5W-40

Winter Front Usage
If a winter front or cold weather cover is to be used, a
percentage of the total grille opening area must be left
uncovered to provide sufficient air flow to the charge air
cooler and automatic transmission oil cooler. The per-
centage of opening must be increased with the increasing
ambient air temperature and/or engine load. If the
cooling fan can be heard cycling frequently, increase the
size of the opening in the winter front. A suitable cold
weather cover is available from your Mopar

t dealer.

Battery Blanket Usage
A battery loses 60% of its cranking power as the battery
temperature decreases to 0°F (-18°). For the same de-
crease in temperature, the engine requires twice as much
power to crank at the same RPM. The use of 120 VAC
powered battery blankets will greatly increase starting
capability at low temperatures. Suitable battery blankets
are available from your authorized Mopar

t dealer.

Arctic Operation
Where there are no provisions to keep the engine warm
when it is operating in ambient temperatures consistently
below (-10°F/-23°C), use 5W-40 synthetic engine oil and
fuel that meets the requirements in Section 7, “Mainte-
nance Procedures,” Engine Oil Selection.

Engine Warm-Up
Avoid full throttle operation when the engine is cold.
When starting a cold engine, bring the engine up to
operating speed slowly to allow the oil pressure to
stabilize as the engine warms up.

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5

NOTE:

High-speed, no-load running of a cold engine

can result in excessive white smoke and poor engine
performance. No-load engine speeds should be kept
under 1,200 rpm during the warm-up period, especially
in cold ambient temperature conditions.

If temperatures are below 32°F (0°C), operate the engine
at moderate speeds for 5 minutes before full loads are
applied.

Engine Idling

Avoid prolonged idling, long periods of idling may be
harmful to your engine because combustion chamber
temperatures can drop so low that the fuel may not burn
completely. Incomplete combustion allows carbon and
varnish to form on piston rings and injector nozzles.
Also, the unburned fuel can enter the crankcase, diluting
the oil and causing rapid wear to the engine.

CAUTION!

Extended periods of idle time may not allow the
vehicle’s exhaust aftertreatment system to properly
regenerate. This can lead to the illumination of the
Malfunction Indicator Light (MIL) or an Electronic
Vehicle Information Center (EVIC) warning message.
Operating the engine for extended periods with the
MIL illuminated or an EVIC warning message dis-
played can cause extensive engine and exhaust sys-
tem damage.

NOTE:

Your vehicle is equipped with a turbo speed

limiter, this feature limits the engine speed to 1200 rpm
when engine coolant temperatures are below 70°F (21°C).
This feature is designed to protect the turbo charger from
damage and will only operate in PARK or NEUTRAL.

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