Dodge 2500 Diesel (2008 year). Manual — part 27

If the WATER IN FUEL LIGHT comes on and a single
chime is heard while you are driving, or with the key in
the ON position, there may be a problem with your water
separator wiring or sensor. See your authorized dealer
for service.

Upon proper draining of the water from the fuel filter, the
WATER IN FUEL LIGHT will remain illuminated for
approximately 10 seconds. If the water was drained
while the engine was running, the water in fuel light may
remain on for approximately three minutes.

NOTE:

Care should be taken in disposing of used fluids

from your vehicle. Used fluids, indiscriminately dis-
carded, can present a problem to the environment. Con-
tact your local 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 a small amount from the fuel/water separator
filter monthly or when the WATER IN FUEL LIGHT is
on. Turn the drain valve located on the bottom of the
filter counterclockwise and allow any accumulated water
to drain into an approved container. Leave the drain
valve open until all water and contaminants have been
removed. Close the drain valve by turning it clockwise
when clean fuel is visible.

NOTE:

The Fuel / Water separator drain valve is

located on the bottom of the fuel filter housing.

If more than a couple ounces of fuel has been drained,
follow the directions below for “Priming if the engine has
run out of fuel.”

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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.

Priming if the engine has run out of fuel

1. Add a substantial quantity of fuel to the tank, approxi-
mately 5 to 10 gallons (19L to 38L).

2. Crank the engine for one to two seconds. If the engine
does not start, then release the key or starter button back
to the RUN position (do not turn the key back to the OFF
position). The electric fuel transfer pump will continue to
run and purge air from the system for about 25 seconds.
After 25 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.

CAUTION!

Do not engage the starter motor for more than 15
seconds at a time. Allow two minutes between the
cranking intervals.

NOTE:

The engine may run rough until the air is forced

from all the fuel lines.

CAUTION!

Diesel fuel will damage black top paving surfaces.
Drain the filter into an appropriate container.

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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.

NOTE:

A maximum blend of 5% biodiesel, meeting

ASTM specification D-6751 may be used with your
Cummins

t Diesel equipped vehicle. Use of biodiesel

mixture in excess of 5% can negatively impact the on-
engine fuel filter’s ability to separate water from the fuel,
resulting in high pressure fuel system corrosion or dam-
age.

NOTE:

As sufficient testing has not been completed,

ethanol blends are not recommended or approved for use
with your Cummins

t Diesel equipped vehicle.

NOTE:

In addition, commercially available fuel addi-

tives are not necessary for the proper operation of your
Cummins

t Diesel equipped vehicle.

Intervention Regeneration Strategy – EVIC
Message Process Flow (Catalyst Full Message)
(6.7L Diesel Engines Only)

Your new Cummins 6.7L diesel meets all EPA Heavy
Duty Diesel Engine Emissions Standards, resulting in the
lowest emitting diesel engine ever produced.

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To achieve these emission standards, your vehicle is
equipped with a state of the art engine and exhaust
system. The engine and exhaust aftertreatment system
work together to achieve the EPA Heavy Duty Diesel
Engine Emissions Standards. These systems are seam-
lessly integrated into your vehicle and managed by the
Cummins

t 6.7L engine Powertrain Control Module

(PCM). The PCM manages engine combustion to allow
the exhaust system’s catalyst to trap and burn Particulate
Matter (PM) pollutants, with no input or interaction on
your part.

Additionally, the overhead console in your vehicle has
the ability to alert you to additional maintenance re-
quired on your truck or engine. Refer to the following
messages that may be displayed on your Electronic
Vehicle Information Center (EVIC):

WARNING!

A hot exhaust system can start a fire if you park over
materials that can burn. Such materials might be
grass or leaves coming into contact with your exhaust
system. Do not park or operate your vehicle in areas
where your exhaust system can contact anything that
can burn.

Perform Service
The 6.7L Cummins

t engine utilizes a Closed Crankcase

Ventilation (CCV) system, EGR valve and an EGR cooler.
This system filters and recycles gasses produced in the
crankcase during the normal combustion process. “Per-
form Service” will be displayed on the overhead console
of your vehicle if the CCV filter, EGR valve and EGR
cooler are due for required maintenance. The CCV filter is

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located on the top of the engine valve cover. For addi-
tional information, see your local authorized dealer.

Catalyst Full See Owner Manual
“Catalyst Full See Owner Manual” will be displayed on
the overhead console of your vehicle if the exhaust
particulate filter reaches 80% of its maximum storage
capacity. Under conditions of exclusive short duration
and low speed driving cycles, your Cummins

t engine

and exhaust aftertreatment system may never reach the
conditions required to remove the trapped PM. If this
occurs, “Catalyst Full See Owner Manual” will be dis-
played on the overhead console in your vehicle. If this
message is displayed you will hear one chime to assist in
alerting you of this condition.

Catalyst Stat::::::::::80%
Catalyst Stat::::::::::80% will replace the message “Catalyst
Full See Owner Manual” after it is displayed for one
minute. The engine Powertrain Control Module (PCM)

will continue to monitor the amount of particulate matter
trapped in the particulate filter. This message indicates
the percentage of the particulate filter capacity that has
been used.

By simply driving your vehicle at highway speeds for as
little as 45 minutes you can remedy the condition in the
particulate filter system and allow your Cummins

t en-

gine and exhaust aftertreatment system to remove the
trapped PM and restore the system to normal operating
condition.

Catalyst Stat:::::::::::80%, 90%, 99%
Catalyst Stat:::::::::::80%, 90%, 99% If you are unable to
drive your vehicle under these conditions for an ex-
tended period of time after the initial warning notifica-
tion, the Engine PCM will continue to monitor the
particulate filter and will display the progression of
particulate filter usage (80, 90, 99%) on the EVIC message
center.

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CATALYST FULL SERVICE REQD
If the particulate filter reaches 99% of its capacity, the
overhead console in your vehicle will chime twice and
display the message CATALYST FULL SERVICE REQD.
At this point the engine PCM will register a fault code,
the instrument panel will display a MIL light and the
engine PCM will derate the truck, reducing its horse-
power and torque output.

The PCM derates the engine in order to limit the likeli-
hood of permanent damage to the aftertreatment system.
If this condition is not corrected and a dealer service is
not performed, extensive exhaust aftertreatment damage
can occur. In order to correct this condition it will be
necessary to have the truck serviced by your local
authorized dealer.

Maintenance Free Batteries

The top of the maintenance free batteries are perma-
nently sealed. You will never have to add water, nor is
periodic maintenance required.

NOTE:

Replacement batteries should both be of equal

capacity to prevent damage to the vehicle’s charging
system.

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WARNING!

• Battery fluid is a corrosive acid solution and can

burn or even blind you. Don’t allow battery fluid
to contact your eyes, skin or clothing. Don’t lean
over a battery when attaching clamps. If acid
splashes in eyes or on skin, flush the area imme-
diately with large amounts of water.

• Battery gas is flammable and explosive. Keep

flame or sparks away from the battery. Don’t use a
booster battery or any other booster source with an
output greater than 12 volts. Don’t allow cable
clamps to touch each other.

• Battery posts, terminals and related accessories

contain lead and lead compounds. Wash hands
after handling.

CAUTION!

• It is essential when replacing the cables on the

battery that the positive cable is attached to the
positive post and the negative cable is attached to
the negative post. Battery posts are marked (+)
positive and (-) negative and identified on the
battery case.

• If a fast charger is used while the battery is in

vehicle, disconnect both vehicle battery cables
before connecting the charger to battery. Do not
use a fast charger to provide starting voltage.

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7

Battery Blanket Usage
A battery loses 60% of its cranking power as the battery
temperature decreases to 0°F (-18°C). 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.

Air Conditioner Maintenance

For best possible performance, your air conditioner
should be checked and serviced by an authorized dealer
at the start of each warm season. This service should
include cleaning of the condenser fins and a performance
test. Drive belt tension should also be checked at this
time.

WARNING!

• Use only refrigerants and compressor lubricants

approved by the manufacturer for your air condi-
tioning system. Some unapproved refrigerants are
flammable and can explode, injuring you. Other
unapproved refrigerants or lubricants can cause
the system to fail, requiring costly repairs. Refer to
Section 3 of the Warranty Information book for
further warranty information.

• The air conditioning system contains refrigerant

under high pressure. To avoid risk of personal
injury or damage to the system, adding refrigerant
or any repair requiring lines to be disconnected
should be done by an experienced repairman.

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NOTE:

Use only manufacturer approved A/C System

Sealers, Stop Leak Products, Seal Conditioners, Compres-
sor Oil, or Refrigerants.

Refrigerant Recovery and Recycling
R-134a Air Conditioning Refrigerant is a hydrofluorocar-
bon (HFC) that is endorsed by the Environmental Pro-
tection Agency and is an ozone-saving product. How-
ever, the manufacturer recommends that air conditioning
service be performed by dealers or other service facilities
using recovery and recycling equipment.

Power Steering — Fluid Check

Checking the power steering fluid level at a defined
service interval is not required. The fluid should only be
checked if a leak is suspected, abnormal noises are
apparent, and/or the system is not functioning as antici-
pated. Coordinate inspection efforts through a certified
DaimlerChrysler Dealership.

WARNING!

Fluid level should be checked on a level surface and
with the engine off to prevent injury from moving
parts and to ensure accurate fluid level reading. Do
not overfill. Use only manufacturer recommended
power steering fluid.

If necessary, add fluid to restore to the proper indicated
level. With a clean cloth, wipe any spilled fluid from all
surfaces. Refer to Fluids, Lubricants, and Genuine Parts
for correct fluid type.

Front Suspension Ball Joints

The ball joints originally supplied with the vehicle are
permanently lubricated at the factory and do not require
service. The ball joints and seals should be inspected
whenever the vehicle is serviced for other reasons.

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Steering Linkage — Inspection

Whenever the vehicle is hoisted all steering linkage joints
should be inspected for evidence of damage. If seals are
damaged, parts should be replaced to prevent leakage or
contamination of the grease.

Front Prop Shaft Lubrication

Lubricate the front driveshaft grease fitting at each oil
change listed in the appropriate maintenance schedule
for your vehicle. Use Mopar

t type MS-6560 (lithium

based grease), or equivalent.

Front Axle Universal Drive Joints And Ball Joints

The front axle universal joint and ball joints are perma-
nently lubricated and do not require servicing.

Front Driveshaft Grease Fitting

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Body Lubrication

Locks and all body pivot points, including such items as
seat tracks, doors, liftgate, tailgate, sliding doors and
hood hinges should be lubricated periodically to assure
quiet, easy operation and to protect against rust and
wear. Prior to the application of any lubricant, the parts
concerned should be wiped clean to remove dust and
grit. After lubricating, excess oil and grease should be
removed. Particular attention should also be given to
hood latching components to ensure proper function.
When performing other underhood services, the hood
latch, release mechanism and safety catch should be
cleaned and lubricated. The external lock cylinders
should be lubricated twice a year, preferably in the fall
and spring. Apply a small amount of a high quality
lubricant such as Mopar

t Lock Cylinder Lubricant di-

rectly into the lock cylinder.

Windshield Wiper Blades

The rubber edges of the wiper blades and the windshield
should be cleaned periodically with a sponge or soft cloth
and a mild nonabrasive cleaner. This will remove accu-
mulations of salt or road film.

Operation of the wipers on dry glass for long periods
may cause deterioration of the wiper blades. Always use
washer fluid when using the wipers to remove salt or dirt
from a dry windshield.

Avoid using the wiper blades to remove frost or ice from
the windshield. Keep the blade rubber out of contact with
petroleum products such as engine oil, gasoline, etc.

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Windshield Washers

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 ra-
diator antifreeze). When refilling the washer fluid reser-
voir, 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.

The washer fluid reservoir will hold a full gallon of fluid
when the Low Washer Fluid Light illuminates.

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.

After the engine has warmed, operate the defroster for a
few minutes to reduce the possibility of smearing or
freezing the fluid on the cold windshield. Mopar

t All

Weather 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.

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Exhaust System

The best protection against carbon monoxide entry into
the vehicle body is a properly maintained engine exhaust
system.

Whenever a change is noticed in the sound of the exhaust
system, when exhaust fumes can be detected inside the
vehicle, or when the underside or rear of the vehicle is
damaged, have a competent mechanic inspect the com-
plete exhaust system and adjacent body areas for broken,
damaged, deteriorated, or mispositioned parts. Open
seams or loose connections could permit exhaust fumes
to seep into the passenger compartment. In addition,
inspect the exhaust system each time the vehicle is raised
for lubrication or oil change. Replace as required.

WARNING!

Exhaust gases can injure or kill you. They contain
carbon monoxide (CO) which is colorless and odor-
less. Breathing it can make you unconscious and can
eventually poison you. To avoid breathing CO, fol-
low the preceding safety tips.

Exhaust System Rubber Isolator and Loop-Type
Hanger — If Equipped
Inspect surfaces whenever the vehicle is hoisted for
rubber to metal separation or deep cracks. If, excessively
deep localized cracks are present, or any part of the
exhaust system abnormally contacts the underbody hard-
ware, the isolator and/or hanger should be replaced.

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Cooling System

WARNING!

You or others can be badly burned by hot coolant or
steam from your radiator. If you see or hear steam
coming from under the hood, don’t open the hood
until the radiator has had time to cool. Never try to
open a cooling system pressure cap when the radiator
is hot.

Engine Coolant Checks
Check the engine coolant (antifreeze) protection every 12
months (before the onset of freezing weather, where
applicable). If coolant is dirty or rusty in appearance, the
system should be drained, flushed and refilled with fresh
coolant. Check the front of the A/C condenser for any

accumulation of bugs, leaves, etc. If dirty, clean by gently
spraying water from a garden hose vertically down the
face of the condenser.

Check the coolant recovery bottle tubing for brittle rub-
ber, cracking, tears, cuts and tightness of the connection
at the bottle and radiator. Inspect the entire system for
leaks.

Extremely cold ambient temperatures may require the
addition of a “winter front” for effective operation of the
cab heating/cooling system. Make certain that a percent-
age of the radiator is exposed for adequate air flow
through the charge air cooler and automatic transmission
oil cooler. The percentage 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.

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Coolant bottle level check
The coolant reserve system provides a quick visual
method of determining that the coolant level is adequate.
With the engine idling and warmed to the normal
operating temperature, the level of the coolant on the
coolant bottle should be between the fluid level marks.
Check the coolant level whenever the hood is raised.

The radiator normally remains completely full, so there is
no longer a need to remove the coolant pressure cap
except for checking coolant freeze point or replacement
with new antifreeze coolant.

WARNING!

Never add coolant to the radiator when the engine is
overheated. Do not loosen or remove pressure cap to
cool overheated engine! The coolant is under pres-
sure and severe scalding could result.

Cooling System — Drain, Flush and Refill
At the intervals shown on the Maintenance Schedules,
the system should be drained, flushed and refilled. See
you authorized dealer for service.

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CAUTION!

The manufacturer highly recommends that all cool-
ing system service, maintenance, and repairs be per-
formed by your local authorized dealer.

If the solution is dirty or contains a considerable amount
of sediment, clean and flush with a reliable cooling
system cleaner. Follow with a thorough rinsing to remove
all deposits and chemicals. Properly dispose of old
antifreeze solution.

Selection Of Coolant
Use only the manufacturer’s recommended coolant; for
correct coolant type, refer to “Engine Coolant” under
“Fluids, Lubricants and Genuine Parts” in this section.

CAUTION!

• Mixing of coolants other than specified HOAT

engine coolants may result in engine damage and
may decrease corrosion protection. If a non-HOAT
coolant is introduced into the cooling system in an
emergency, it should be replaced with the speci-
fied coolant as soon as possible.

• Do not use plain water alone or alcohol-base

engine coolant (antifreeze) products. Do not use
additional rust inhibitors or antirust products, as
they may not be compatible with the radiator
engine coolant and may plug the radiator.

• This vehicle has not been designed for use with

Propylene Glycol based coolants. Use of Propy-
lene Glycol based coolants is not recommended.

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