Dodge 3500 Diesel (2008 year). Manual

Required Maintenance For Noise Control Systems
The following maintenance services must be performed
every 6 months or 6,000 miles (9 600 km), whichever
comes first, to assure proper operation of the noise
control systems. In addition, inspection and service
should be performed anytime a malfunction is observed
or suspected. Proper maintenance of the entire vehicle
will help the effectiveness of the noise control systems.

Exhaust System
Inspect the entire exhaust system for leaks and damaged
parts. Devices such as hangers, clamps, and U-bolts
should be tight and in good condition. Damaged compo-
nents, burned or blown out mufflers, burned or rusted
out exhaust pipes should be replaced according to the
procedures and specifications outlined in the appropriate
service manual.

Air Cleaner Assembly
Inspect air cleaner housing for proper assembly and fit.
Make certain that the air cleaner is properly positioned
and that the cover is tight. Check all hoses leading to the
air cleaner for tightness. The air filter element must also
be clean and serviced according to the instructions out-
lined in the Maintenance Schedule Section of this
manual.

Tampering With Noise Control System Prohibited
Federal law prohibits the following acts or the causing
thereof: (1) the removal or rendering inoperative by any
person, other than for purposes of maintenance, repair, or
replacement, of any device or element of design incorpo-
rated into any new vehicle for the purpose of noise
control prior to its sale or delivery to the ultimate
purchaser or while it is in use, or (2) the use of the vehicle
after such device or element of design has been removed
or rendered inoperative by any person.

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Among those acts presumed to constitute tampering are
the acts listed below.

• AIR CLEANER

− Removal of the air cleaner.

− Removal of the air cleaner filter element from the air

cleaner housing.

− Removal of the air ducting.

• EXHAUST SYSTEM

− Removal or rendering inoperative exhaust system

components, including the muffler or tailpipe.

• ENGINE COOLING SYSTEM

− Removal or rendering inoperative the fan clutch.

− Removal of the fan shroud.

Noise Emission Warranty
The manufacturer warrants that this vehicle as manufac-
tured by the manufacturer, was designed, built and
equipped to conform at the time it left the manufacturer’s
control with all applicable U.S. EPA Noise Control Regu-
lations.

This warranty covers this vehicle as designed, built and
equipped by the manufacturer, and is not limited to any
particular part, component or system of the vehicle
manufactured by the manufacturer. Defects in design,
assembly or in any part, component or system of the
vehicle as manufactured by the manufacturer, which, at
the time it left the manufacturer’s control, caused noise
emissions to exceed Federal standards, are covered by
this warranty for the life of the vehicle.

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453

Maintenance Log and Service Chart (Diesel Engines)

Noise Systems Maintenance Chart and Service Log — Insert Month, Day, Year under column mileage closest to the

mileage at which service was performed.
MILES

7,500

15,000

22,500

30,000

37,500

45,000

52,500

60,000

KILOMETERS

12 000

24 000

36 000

48 000

60 000

72 000

84 000

96 000

Exhaust system-inspect
Air cleaner assembly-inspect
ODOMETER READING
PERFORMED BY
PERFORMED AT

MILES

67,500

75,000

82,500

90,000

97,500

84,000

105,00

112,500

KILOMETERS

108 000 120 000 132 000 144 000 126 000 156 000 168 000 181 000

Exhaust system-inspect
Air cleaner assembly-inspect
ODOMETER READING
PERFORMED BY
PERFORMED AT

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MAINTAINING YOUR VEHICLE

Appearance Care and Protection from Corrosion

Protection of Body and Paint from Corrosion
Vehicle body care requirements vary according to geo-
graphic locations and usage. Chemicals that make roads
passable in snow and ice, and those that are sprayed on
trees and road surfaces during other seasons, are highly
corrosive to the metal in your vehicle. Outside parking,
which exposes your vehicle to airborne contaminants,
road surfaces on which the vehicle is operated, extreme
hot or cold weather and other extreme conditions will
have an adverse effect on paint, metal trim, and under-
body protection.

The following maintenance recommendations will enable
you to obtain maximum benefit from the corrosion
resistance built into your vehicle.

What Causes Corrosion?
Corrosion is the result of deterioration or removal of
paint and protective coatings from your vehicle.

The most common causes are:
• Road salt, dirt and moisture accumulation.
• Stone and gravel impact.
• Insects, tree sap and tar.
• Salt in the air near seacoast localities.
• Atmospheric fallout/industrial pollutants.

Washing
• Wash your vehicle regularly. Always wash your ve-

hicle in the shade using Mopar

t Car Wash or a mild

car wash soap, and rinse the panels completely with
clear water.

• If insects, tar or other similar deposits have accumu-

lated on your vehicle, use Mopar

t Super Kleen Bug

and Tar Remover to remove.

• Use Mopart Cleaner Wax to remove road film, stains

and to protect your paint finish. Take care never to
scratch the paint.

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455

• Avoid using abrasive compounds and power buffing

that may diminish the gloss or thin out the paint
finish.

CAUTION!

Do not use abrasive or strong cleaning materials such
as steel wool or scouring powder which will scratch
metal and painted surfaces.

Special Care

• If you drive on salted or dusty roads or if you drive

near the ocean, hose off the undercarriage at least once
a month.

• It is important that the drain holes in the lower edges

of the doors, rocker panels and trunk be kept clear and
open.

• If you detect any stone chips or scratches in the paint,

touch them up immediately. The cost of such repairs is
considered the responsibility of the owner.

• If your vehicle is damaged due to an accident or

similar cause which destroys the paint and protective
coating, have your vehicle repaired as soon as pos-
sible. The cost of such repairs is considered the respon-
sibility of the owner.

• If you carry special cargo such as chemicals, fertilizers,

de-icer salt, etc., be sure that such materials are well
packaged and sealed.

• If a lot of driving is done on gravel roads, consider

mud or stone shields behind each wheel.

• Use Mopart touch up paint on scratches as soon as

possible. Your dealer has touch up paint to match the
color of your vehicle.

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MAINTAINING YOUR VEHICLE

Wheel and Wheel Trim Care
All wheels and wheel trim, especially aluminum and
chrome plated wheels should be cleaned regularly with a
mild soap and water to prevent corrosion. To remove
heavy soil, use Mopar

t Wheel Cleaner or select a non-

abrasive, non-acidic cleaner. Do not use scouring pads,
steel wool, a bristle brush or metal polishes. Only
Mopar

t cleaners are recommended. Do not use oven

cleaner. Avoid automatic car washes that use acidic
solutions or harsh brushes that may damage the wheels’
protective finish.

YES Essentials

t Fabric Cleaning Procedure – If

equipped
YES Essentials

t seats may be cleaned in the following

manner:

• Remove as much of the stain as possible by blotting

with a clean, dry towel.

• Blot any remaining stain with a clean, damp towel.
• For tough stains, apply Mopart Total Clean or a mild

soap solution to a clean, damp cloth and remove stain.
Use a fresh, damp towel to remove soap residue.

• For grease stains, apply Mopart Multi-purpose

cleaner to a clean, damp cloth and remove stain. Use a
fresh, damp towel to remove soap residue.

• Do not use any solvents or protectants on Yes Essen-

tials products.

Interior Care
Use Mopar

t Total Clean to clean fabric upholstery and

carpeting.

Use Mopar

t Total Clean to clean vinyl upholstery.

Mopar

t Total Clean is specifically recommended for

leather upholstery.

MAINTAINING YOUR VEHICLE

457

Your leather upholstery can be best preserved by regular
cleaning with a damp soft cloth. Small particles of dirt
can act as an abrasive and damage the leather upholstery
and should be removed promptly with a damp cloth.
Stubborn soils can be removed easily with a soft cloth
and Mopar

t Total Clean. Care should be taken to avoid

soaking your leather upholstery with any liquid. Please
do not use polishes, oils, cleaning fluids, solvents, deter-
gents, or ammonia based cleaners to clean your leather
upholstery. Application of a leather conditioner is not
required to maintain the original condition.

WARNING!

Do not use volatile solvents for cleaning purposes.
Many are potentially flammable, and if used in
closed areas they may cause respiratory harm.

Glass Surfaces
All glass surfaces should be cleaned on a regular basis
with Mopar

t Glass Cleaner or any commercial

household-type glass cleaner. Never use an abrasive type
cleaner. Use caution when cleaning the inside rear win-
dow equipped with electric defrosters or the right rear
quarter window equipped with the radio antenna. Do
not use scrapers or other sharp instruments which may
scratch the elements. When cleaning the rearview mirror,
spray cleaner on the towel or rag that you are using. Do
not spray cleaner directly on the mirror.

Cleaning Plastic Instrument Cluster Lenses
The lenses in front of the instruments in this vehicle are
molded in clear plastic. When cleaning the lenses, care
must be taken to avoid scratching the plastic.

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MAINTAINING YOUR VEHICLE

1. Clean with a wet soft rag. A mild soap solution may be
used, but do not use high alcohol content or abrasive
cleaners. If soap is used, wipe clean with a clean damp
rag.

2. Dry with a soft tissue.

Seat Belt Maintenance
Do not bleach, dye or clean the belts with chemical
solvents or abrasive cleaners. This will weaken the fabric.
Sun damage can also weaken the fabric.

If the belts need cleaning, use a mild soap solution or
lukewarm water. Do not remove the belts from the car to
wash them.

Replace the belts if they appear frayed or worn or if the
buckles do not work properly.

Dry with a soft tissue.

FUSES (INTEGRATED POWER MODULE)

An integrated power module is located in the engine
compartment near the battery. This center contains car-
tridge fuses and mini fuses. A description of each fuse
and component may be stamped on the inside cover,
otherwise the cavity number of each fuse is stamped on
the inside cover that corresponds to the following chart.

Integrated Power Module Location

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459

Cavity Cartridge

Fuse

Mini

Fuse

Description

20 Amp
Yellow

Power Outlet Console

20 Amp
Yellow

Cabin Compartment
Node (CCN) Door
Locks

—

15 Amp
Blue

Aisin Transmission
Controls (Diesel Only)

20 Amp
Yellow

Power Sunroof

10 Amp
Red

Vistronic Fan/
Wastegate Solenoid

—

10 Amp
Red

Heated Mirrors

Cavity Cartridge

Fuse

Mini

Fuse

Description

30 Amp
Pink

Off Road Module
Power

5 Amp
Orange

Trx-Off Rd Pkg Sen
(Gas Engine Only)
NOTE: Insert 5 amp
fuse in this cavity to
enable the TRX capa-
bility (If Equipped).

20 Amp
Yellow

Ignition Off Draw
(IOD)-Cabin Com-
partment Node
(CCN)/Radio/Under
Hood Lamp/Wireless
Control Module
(WCM)/Satellite Digi-
tal Audio Receiver
(SDARS)/Hands Free
Module (HFM)/EOM

460

MAINTAINING YOUR VEHICLE

Cavity Cartridge

Fuse

Mini

Fuse

Description

30 Amp
Pink

Electric Brake

25 Amp
Natural

Power-Battery
RWAL/ABS Module
Feed

15 Amp
Blue

Park Lights Left

20 Amp
Yellow

Trailer Park Lights

15 Amp
Blue

Park Lights Right

—

40 Amp
Green

ABS Pump

30 Amp
Pink

Trailer Tow Battery
Feed

Cavity Cartridge

Fuse

Mini

Fuse

Description

10 Amp
Red

Occupant Restraints
Controller (ORC) 2

10 Amp
Red

Occupant Restraints/
Pass Disable Switch

2 Amp
Gray

IGN Switch Feed

10 Amp
Red

HVAC

20 Amp
Blue

AISIN Relay Feed
(Diesel Only)

10 Amp
Red

Power Mirror/T-Case
Brake

20 Amp
Yellow

Brake Switch/Center
High Mount Stop
Light (CHMSL)/
Aftermarket CHMSL

MAINTAINING YOUR VEHICLE

461

Cavity Cartridge

Fuse

Mini

Fuse

Description

40 Amp
Green

Power Seats

10 Amp
Red

Power Run/Start-
PCM/Steering Angle
Sensor

10 Amp
Red

4X4 Switch/Pass Dr
Switch/EC Mirror

15 Amp
Blue

Power Run/Start-
ABS/RWAL/Smart
Bar/YAW Sensor/
Universal Exhaust
Gas Oxygen (Uego)
Sensor Controller

10 Amp
Red

PCM (Gas)/TCM
(Diesel 58RFE)

Cavity Cartridge

Fuse

Mini

Fuse

Description

10 Amp
Red

Power Ignition Run
— Adjustable Pedals
LED

10 Amp
Red

Power-IGN Run —
HVAC

—

15 Amp
Blue

Cabin Compartment
Node (CCN) Illumi-
nation

25 Amp
Natural

Audio_Amplifier

15 Amp
Blue

Variable Gate Turbo
(VGT) — Turbo Die-
sel

20 Amp
Yellow

Power Outlet IP

462

MAINTAINING YOUR VEHICLE

Cavity Cartridge

Fuse

Mini

Fuse

Description

10 Amp
Red

Seatbelt Tension
Reducer/Power IGN
Run/Acc

20 Amp
Yellow

Power IGN Run/Acc
— Cigar Lighter/Rear
Power Point

—

30 Amp
Pink

Diesel PCM (Diesel
Only)

CAUTION!

• When installing the Integrated Power Module

cover, it is important to ensure the cover is prop-
erly positioned and fully latched. Failure to do so
may allow water to get into the Integrated Power
Module, and possibly result in a electrical system
failure.

• When replacing a blown fuse, it is important to

use only a fuse having the correct amperage rating.
The use of a fuse with a rating other than indicated
may result in a dangerous electrical system over-
load. If a properly rated fuse continues to blow, it
indicates a problem in the circuit that must be
corrected.

MAINTAINING YOUR VEHICLE

463

VEHICLE STORAGE

If you are storing your vehicle for more than 21 days, we
recommend that you take the following steps to mini-
mize the drain on your vehicle’s battery:

• Disconnect the Ignition-Off Draw fuse (IOD) fuse

located in the Integrated Power Module, located in the
engine compartment. The IOD cavity includes a
snap-in retainer that allows the fuse to be discon-
nected, without removing it from the fuse block.

• The electronic shift transfer case should be placed in

the 4HI mode and kept in this position to minimize the
battery drain.

• As an alternative to the above steps you may discon-

nect the negative cables from both batteries.

• Any time you store your vehicle, or keep it out of

service (i.e., vacation) for two weeks or more, run the
air conditioning system at idle for about five minutes

in the fresh air and high blower setting. This will
ensure adequate system lubrication to minimize the
possibility of compressor damage when the system is
started again.

NOTE:

When reinstalling the IOD fuse push firmly until

fully seated; the gauges in the instrument cluster will do
a full sweep when the ignition key is cycled to RUN. This
is a normal condition.

NOTE:

When the vehicle is shipped from the factory,

the IOD fuse is in the up, or extracted position. If the
radio, interior lamps, keyless entry, or other features do
not work with the key OFF, check the position of the fuse
(or check to see if the fuse is blown) to ensure that it is
fully seated. When the IOD fuse is extracted, the instru-
ment cluster in the odometer window will display

9NO

FUSE.”

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MAINTAINING YOUR VEHICLE

REPLACEMENT LIGHT BULBS

LIGHT BULBS — Inside

Bulb No.

Overhead Console Lights . . . . . . . . . . . . . . . TS 212-2
Dome Light. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7679

All of the inside bulbs are brass or glass wedge base.
Aluminum base bulbs are not approved.

LIGHT BULBS — Outside

Bulb No.

Back-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3057
Center High Mounted Stop Light . . . . . . . . . . . . . 912
Fog Light . . . . . . . . . . . . . . . . . . . . . . . . . . . 9006LL
Headlight (Halogen) . . . . . . . . . . . . . . . . . . . . . . H13
Side Marker Bulb . . . . . . . . . . . . . . . . . . . . . . . W5W
Park & Turn Signal . . . . . . . . . . . . . . . . . . . 3157NAK
Rear License Plate Light. . . . . . . . . . . . . . . . . . . . 168
Rear Cargo Light. . . . . . . . . . . . . . . . . . . . . . . . . 912
Tail & Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3057
Cab Clearance Lights . . . . . . . . . . . . . . . . . . . . . . 168
Dual Rear Wheel Sidemarker Light . . . . . . . . . . . . 168
Dual Rear Wheel Tailgate ID Lights (3) . . . . . . . . . 168

MAINTAINING YOUR VEHICLE

465

BULB REPLACEMENT

Headlight (Halogen)/Front Park and Turn Lights

CAUTION!

This is a halogen bulb. Avoid touching the glass with
your fingers. Reduced bulb life will result.

1. Open the hood

2. Remove the two bolts from the front of the headlight
housing.

Front Headlight Housing Bolts

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MAINTAINING YOUR VEHICLE

Dodge 3500 Diesel (2008 year). Manual - part 29