Dodge 3500 Diesel (2008 year). Manual - part 26

MAINTAINING YOUR VEHICLE

CONTENTS

m Engine Compartment — 6.7L Diesel Engine . . . . 408
m Onboard Diagnostic System (OBD II) . . . . . . . . . 409
m Replacement Parts . . . . . . . . . . . . . . . . . . . . . . 409
m Engine Data Plate . . . . . . . . . . . . . . . . . . . . . . 410
m Authorized Dealer Service . . . . . . . . . . . . . . . . 410
m Service Information . . . . . . . . . . . . . . . . . . . . . 410
m Maintenance Procedures . . . . . . . . . . . . . . . . . . 412

▫ Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . 413
▫ Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . 418

▫ Engine Air Cleaner Filter (6.7L Diesel

Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419

▫ Draining Fuel/Water Separator Filter (6.7L

Diesel Engine) . . . . . . . . . . . . . . . . . . . . . . . 422

▫ Intervention Regeneration Strategy – EVIC

Message Process Flow (Catalyst Full Message)
(6.7L Diesel Engines Only) . . . . . . . . . . . . . . . 425

▫ Maintenance Free Batteries . . . . . . . . . . . . . . . 428
▫ Air Conditioner Maintenance . . . . . . . . . . . . . 430
▫ Power Steering — Fluid Check . . . . . . . . . . . . 431

▫ Front Suspension Ball Joints . . . . . . . . . . . . . . 431
▫ Steering Linkage — Inspection . . . . . . . . . . . . 432
▫ Front Prop Shaft Lubrication . . . . . . . . . . . . . 432
▫ Front Axle Universal Drive Joints And Ball

Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432

▫ Body Lubrication . . . . . . . . . . . . . . . . . . . . . 433
▫ Windshield Wiper Blades . . . . . . . . . . . . . . . . 433
▫ Windshield Washers . . . . . . . . . . . . . . . . . . . 434
▫ Exhaust System . . . . . . . . . . . . . . . . . . . . . . 435
▫ Cooling System . . . . . . . . . . . . . . . . . . . . . . . 436
▫ Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442
▫ Charge Air Cooler (Inter-Cooler) . . . . . . . . . . 442
▫ Hoses And Vacuum/Vapor Harnesses . . . . . . . 443

▫ Brake System . . . . . . . . . . . . . . . . . . . . . . . . 443
▫ Clutch Linkage . . . . . . . . . . . . . . . . . . . . . . . 445
▫ Clutch Hydraulic System . . . . . . . . . . . . . . . . 445
▫ Rear Axle And 4X4 Front Driving Axle Fluid

Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446

▫ Transfer Case — If Equipped . . . . . . . . . . . . . 446
▫ Manual Transmission — If Equipped . . . . . . . 447
▫ Automatic Transmission . . . . . . . . . . . . . . . . 447
▫ Front Wheel Bearings . . . . . . . . . . . . . . . . . . 450
▫ Noise Control System Required Maintenance

& Warranty . . . . . . . . . . . . . . . . . . . . . . . . . 451

▫ Appearance Care And Protection From

Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . 455

m Fuses (Integrated Power Module) . . . . . . . . . . . 459

406

MAINTAINING YOUR VEHICLE

m Vehicle Storage . . . . . . . . . . . . . . . . . . . . . . . . 464
m Replacement Light Bulbs . . . . . . . . . . . . . . . . . 465
m Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . 466

▫ Headlight (Halogen)/Front Park And Turn

Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 466

▫ Fog Lights . . . . . . . . . . . . . . . . . . . . . . . . . . 469
▫ Tail, Stop, Turn And Backup Lights . . . . . . . . . 470
▫ Center High-Mounted Stoplight (CHMSL)

With Cargo Light . . . . . . . . . . . . . . . . . . . . . 473

▫ Cab Top Clearance Lights — If Equipped . . . . 474

▫ Tailgate ID Lights (Dual Rear Wheels) — If

Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . . 476

▫ Rear Light Bar ID Marker (Dual Rear Wheel) —

If Equipped . . . . . . . . . . . . . . . . . . . . . . . . . 477

▫ Side Marker Lights (Dual Rear Wheels) . . . . . . 478

m Fluid Capacities . . . . . . . . . . . . . . . . . . . . . . . . 479
m Fluids, Lubricants And Genuine Parts . . . . . . . . 480

▫ Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480
▫ Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . 482

MAINTAINING YOUR VEHICLE

407

ENGINE COMPARTMENT — 6.7L DIESEL ENGINE

408

MAINTAINING YOUR VEHICLE

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

t parts for normal/scheduled

maintenance and repairs is highly recommended to en-
sure the designed performance. Damage or failures
caused by the use of non-Mopar

t parts for maintenance

and repairs will not be covered by the manufacturer’s
warranty.

MAINTAINING YOUR VEHICLE

409

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.

AUTHORIZED DEALER SERVICE

Your authorized dealer has the qualified service person-
nel, special tools and equipment to perform all service
operations in an expert manner. Service manuals are
available which include detailed service information for
your vehicle. Refer to these manuals 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

t Fluids, Lubricants and Parts are available from your

authorized dealer and will help you keep your vehicle
operating at its best. Your authorized dealer also has the
qualified service personnel, special tools and equipment to
perform all service operations in an expert manner. Service
manuals are available which include detailed service infor-
mation for your vehicle. Refer to these manuals before
attempting any procedure yourself. See Service Publications
information at the back of this manual.

410

MAINTAINING YOUR VEHICLE

CAUTION!

To maintain your vehicle safely follow these guide-
lines:
• Watch your vehicle’s mileage and check your

Maintenance Schedules regularly for required ser-
vicing. Excessive 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 undercoating with solvent.

• If you have your vehicle undercoated, make sure

no undercoating material is sprayed on the ex-
haust system or components of the seat belt
system.

NOTE:

It is not possible for the manufacturer and

Cummins, Inc

t. to anticipate every possible circumstance

that can involve a potential hazard.

MAINTAINING YOUR VEHICLE

411

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.

• 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.

• Important: All maintenance other than that listed in this manual, as

well as some procedures listed here, MUST be performed by your
authorized dealer. Your authorized dealer has been trained and has
the necessary parts to maintain your engine.

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.

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.

412

MAINTAINING YOUR VEHICLE

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).

CAUTION!

Overfilling or underfilling the crankcase will cause
oil aeration or loss of oil pressure. This could damage
your engine.

MAINTAINING YOUR VEHICLE

413

Never operate the engine with oil level below the “ADD”
mark or above the upper “SAFE” mark.

Change Engine Oil (6.7L Diesel Engine)
Follow the 6.7L Diesel Maintenance Schedule for recom-
mended engine oil change intervals.

Engine Oil Selection (6.7L Diesel Engines)
For best performance and maximum protection under all
types of operating conditions, the manufacturer only
recommends engine oils that are API CJ-4 certified and
meet the requirements of DaimlerChrysler. Use Mopar

or an equivalent oil meeting DaimlerChrysler Material
Standards MS-10902. Products meeting Cummins

t CES

20081 may also be used. The identification of these
engine oils are typically located 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 CJ-4 certified
engine 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.

414

MAINTAINING YOUR VEHICLE

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

t 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
same requirements as stated previously. The engine oil
filler cap also shows the recommended engine oil viscos-
ity for your engine. For information on engine oil filler
cap location, refer to the “Engine Compartment” illustra-
tion in this section.

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 manufacturer strongly recommends against the ad-
dition 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.

MAINTAINING YOUR VEHICLE

415

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.

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

t 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.

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MAINTAINING YOUR VEHICLE

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.

Install the filter as specified by the filter manufacturer.
Turn the filter 3/4 to one full turn after making contact
with the gasket.

Check the condition of the threads and sealing surface on
the oil pan and drain plug.

Install the drain plug and sealing washer and tighten to
37 ft-lbs. (50 N·m).

Use only high-quality multi-grade lubricating oil in your
Cummins

t Diesel Engine. Choose the correct oil for your

operating conditions as outlined in the Selection of
Engine Oil.

Cummins

t Turbo Diesel

Fill the engine with the correct grade of new oil. The
engine capacity is 11 quarts (10.4 liters) in the crankcase
and 1 quart (.95 liter) in the lubricating oil filter.

MAINTAINING YOUR VEHICLE

417

Start the engine and operate it at idle for several minutes.
Check for leaks at the lubricating oil filter and oil pan
drain plug.

Run the engine until it has reached operating tempera-
ture, stop the engine. Wait approximately 15 minutes to
let the oil in the upper parts of the engine drain back to
the pan. Check the oil level again.

Add oil as necessary to bring the level to the “SAFE”
mark on the dipstick.

Disposing Of Used Engine Oil And Filter
Care should be taken in disposing of used engine oil and
oil filters from your vehicle. Used oil and oil filters,
indiscriminately discarded, can present a problem to the
environment. Contact your authorized dealer, service
station, or governmental agency for advice on how and
where used oil and oil filters can be safely discarded in
your area.

Drive Belt

Inspection
Check the belt for intersecting cracks.

• Transverse (across the belt width) cracks are accept-

able.

• Longitudinal (direction of belt length) cracks that

intersect with transverse cracks are NOT acceptable.

Replace the belt if it has unacceptable cracks, is frayed or
has pieces of material missing.

The engine speed sensor, located near the damper, should
be inspected for damage if a belt is frayed.

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MAINTAINING YOUR VEHICLE

Engine Air Cleaner Filter (6.7L Diesel Engines)

CAUTION!

All air entering the engine intake must be filtered.
The abrasive particles in unfiltered air will cause
rapid wear to engine components.

The condition of the air cleaner filter is monitored by the
Engine Control Module. The Electronic Vehicle Informa-
tion Center (EVIC) will display SERVICE AIR FILTER
when service is required.

Do not remove the top of the air filter housing to
inspect the filter element on your diesel engine under
normal operating conditions.

The EVIC message SERVICE AIR FILTER could be dis-
played periodically. This is because engine air flow
requirements change based on driving conditions. As the

filter becomes more restrictive and air flow requirements
increase the EVIC message SERVICE AIR FILTER will be
displayed. The message may not be displayed in subse-
quent drive cycles if the same conditions are not met. The
air filter element should be replaced within 250 miles
from the first time this message is displayed to ensure
proper engine operation during all driving conditions.

The air filter housing on your vehicle may also come
equipped with a Filter Minder™. This is an air flow
restriction gauge that will indicate when the filter ele-
ment needs to be replaced.

CAUTION!

Driving with a restricted air filter can cause engine
damage.

MAINTAINING YOUR VEHICLE

419

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