DODGE RAM 3500 DIESEL 2009 4.G Owners Manual

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. They contain carbon
monoxide (CO) which is colorless and odorless.
Breathing it can make you unconscious and can
eventually poison you. To avoid breathing CO, refer
to “Exhaust Gas” in the “Safety Tips” section of this
manual.The catalytic converter requires the use of unleaded fuel
only. Leaded gasoline will destroy the effectiveness of the
catalyst as an emission control device.
Under normal operating conditions, the catalytic con-
verter will not require maintenance. However, it is im-
portant to keep the engine properly tuned to assure
proper catalyst operation and prevent possible catalyst
damage.
MAINTAINING YOUR VEHICLE 439
7

CAUTION!
Damage to the catalytic converter can result if your
vehicle is not kept in proper operating condition. In
the event of engine malfunction, particularly involv-
ing engine misfire or other apparent loss of perfor-
mance, have your vehicle serviced promptly. Contin-
ued operation of your vehicle with a severe
malfunction could cause the converter to overheat,
resulting in possible damage to the converter and the
vehicle.
NOTE: Intentional tampering with emissions control
systems can result in civil penalties being assessed
against you.
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.
In unusual situations involving grossly malfunctioning
engine operation, a scorching odor may indicate severe
and abnormal catalyst overheating. If this occurs, the
vehicle should be stopped, the engine shut off and the
vehicle allowed to cool. Thereafter, service, including a
tune-up to manufacturer’s specifications, should be ob-
tained immediately.
440 MAINTAINING YOUR VEHICLE

To minimize the possibility of catalyst damage:•
Do not shut off the engine or interrupt the ignition
when the transmission is in gear and the vehicle is in
motion.
•
Do not try to start the engine by pushing or towing the
vehicle.
•
Do not idle the engine with any spark plug wires
disconnected or removed, such as when diagnostic
testing, or for prolonged periods during very rough
idling or malfunctioning operating conditions.
Cooling System
WARNING!
You or others can be badly burned by hot engine
coolant (antifreeze) or steam from your radiator. If
you see or hear steam coming from under the hood,
do not 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 ChecksCheck the engine coolant (antifreeze) protection every
12 months (before the onset of freezing weather, where
applicable). If the engine coolant (antifreeze) is dirty or
rusty in appearance, the system should be drained,
flushed and refilled with fresh engine coolant (anti-
freeze). Check the front of the A/C condenser for any
MAINTAINING YOUR VEHICLE 441
7

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.
With the engine at normal operating temperature (but
not running), check the cooling system pressure cap for
proper vacuum sealing by draining a small amount of
engine coolant (antifreeze) from the radiator drain cock.
If the cap is sealing properly, the engine coolant (anti-
freeze) will begin to drain from the coolant recovery
bottle. DO NOT REMOVE THE COOLANT PRESSURE
CAP WHEN THE COOLING SYSTEM IS HOT.
Cooling System — Drain, Flush and RefillIf the engine coolant (antifreeze) 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 the old engine coolant (antifreeze) solution.
Refer to the “Maintenance Schedule” in Section 8 for the
proper maintenance intervals.Selection Of CoolantUse only the manufacturer’s recommended engine cool-
ant (antifreeze). Refer to “Fluids, Lubricants, and Genu-
ine Parts” in this section for the correct fluid type.
442 MAINTAINING YOUR VEHICLE

CAUTION!
•
Mixing of engine coolant (antifreeze) other than
specified HOAT engine coolant (antifreeze), may
result in engine damage and may decrease corro-
sion protection. If a non-HOAT engine coolant
(antifreeze) is introduced into the cooling system
in an emergency, it should be replaced with the
specified engine coolant (antifreeze) as soon as
possible.
•
Do not use water alone or alcohol-based engine
coolant (antifreeze) products. Do not use addi-
tional rust inhibitors or antirust products, as they
may not be compatible with the radiator engine
coolant (antifreeze) and may plug the radiator.(Continued)
CAUTION! (Continued)
•
This vehicle has not been designed for use with
Propylene Glycol based engine coolant (anti-
freeze). Use of Propylene Glycol based engine
coolant (antifreeze) is not recommended.
Adding CoolantYour vehicle has been built with an improved engine
coolant (antifreeze) that allows extended maintenance
intervals. This engine coolant (antifreeze) can be used up
to 5 Years or 102,000 miles (170 000 km) before replace-
ment. To prevent reducing this extended maintenance
period, it is important that you use the same engine
coolant (antifreeze) throughout the life of your vehicle.
Please review these recommendations for using Hybrid
Organic Additive Technology (HOAT) engine coolant
(antifreeze).
MAINTAINING YOUR VEHICLE 443
7

When adding engine coolant (antifreeze):•
The manufacturer recommends using MOPAR
Antifreeze/Coolant 5 Year/100,000 Mile Formula
HOAT (Hybrid Organic Additive Technology).
•
Mix a minimum solution of 50% HOAT engine coolant
(antifreeze) and distilled water. Use higher concentra-
tions (not to exceed 70%) if temperatures below -34°F
(-37°C) are anticipated.
•
Use only high purity water such as distilled or deion-
ized water when mixing the water/engine coolant
(antifreeze) solution. The use of lower quality water
will reduce the amount of corrosion protection in the
engine cooling system.
Please note that it is the owner’s responsibility to main-
tain the proper level of protection against freezing ac-
cording to the temperatures occurring in the area where
the vehicle is operated. NOTE:
Mixing engine coolant (antifreeze) types will
decrease the life of the engine coolant (antifreeze) and
will require more frequent engine coolant (antifreeze)
changes.
Cooling System Pressure CapThe cap must be fully tightened to prevent loss of engine
coolant (antifreeze), and to ensure that engine coolant
(antifreeze) will return to the radiator from the coolant
recovery bottle.
The cap should be inspected and cleaned if there is any
accumulation of foreign material on the sealing surfaces.
444 MAINTAINING YOUR VEHICLE

WARNING!
•
The warning words “DO NOT OPEN HOT” on
the cooling system pressure cap are a safety pre-
caution. Never add engine coolant (antifreeze)
when the engine is overheated. Do not loosen or
remove the cap to cool an overheated engine. Heat
causes pressure to build up in the cooling system.
To prevent scalding or injury, do not remove the
pressure cap while the system is hot or under
pressure.
•
Do not use a pressure cap other than the one
specified for your vehicle. Personal injury or en-
gine damage may result.
Disposal of Used Engine CoolantUsed ethylene glycol-based engine coolant (antifreeze) is
a regulated substance requiring proper disposal. Check
with your local authorities to determine the disposalrules for your community. To prevent ingestion by ani-
mals or children do not store ethylene glycol-based
engine coolant (antifreeze) in open containers or allow it
to remain in puddles on the ground. If ingested by a
child, contact a physician immediately. Clean up any
ground spills immediately.
Coolant LevelThe coolant bottle provides a quick visual method for
determining that the engine coolant (antifreeze) level is
adequate. With the engine cold, the level of the engine
coolant (antifreeze) in the coolant recovery bottle should
be between the ranges indicated on the bottle.
The radiator normally remains completely full, so there is
no need to remove the radiator cap unless checking for
engine coolant (antifreeze) freeze point or replacing en-
gine coolant (antifreeze). Advise your service attendant
of this. As long as the engine operating temperature is
satisfactory, the coolant bottle only needs to be checked
once a month.
MAINTAINING YOUR VEHICLE 445
7

When additional engine coolant (antifreeze) is needed to
maintain the proper level, it should be added to the
coolant bottle. Do not overfill.Points To RememberNOTE:When the vehicle is stopped after a few miles (a
few kilometers) of operation, you may observe vapor
coming from the front of the engine compartment. This is
normally a result of moisture from rain, snow, or high
humidity accumulating on the radiator and being vapor-
ized when the thermostat opens, allowing hot engine
coolant (antifreeze) to enter the radiator.
If an examination of your engine compartment shows no
evidence of radiator or hose leaks, the vehicle may be
safely driven. The vapor will soon dissipate.•
Do not overfill the coolant recovery bottle.
•
Check the engine coolant (antifreeze) freeze point in
the radiator and in the coolant recovery bottle. If engine coolant (antifreeze) needs to be added, the
contents of the coolant recovery bottle must also be
protected against freezing.
•
If frequent engine coolant (antifreeze) additions are
required, or if the level in the coolant recovery bottle
does not drop when the engine cools, the cooling
system should be pressure tested for leaks.
•
Maintain engine coolant (antifreeze) concentration at
50% HOAT engine coolant (antifreeze) (minimum)
and distilled water for proper corrosion protection of
your engine, which contains aluminum components.
•
Make sure that the radiator and coolant recovery
bottle overflow hoses are not kinked or obstructed.
•
Keep the front of the radiator clean. If your vehicle is
equipped with air conditioning, keep the front of the
condenser clean.
446 MAINTAINING YOUR VEHICLE

•
Do not change the thermostat for Summer or Winter
operation. If replacement is ever necessary, install
ONLY the correct type thermostat. Other designs may
result in unsatisfactory coolant performance, poor gas
mileage, and increased emissions.
Brake System
Master Cylinder — Brake Fluid Level CheckThe fluid level of the master cylinder should be checked
when performing under the hood service, or immedi-
ately if the brake system warning lamp indicates system
failure.
The brake master cylinder has a translucent plastic
reservoir. On the outboard side of the reservoir, there is a
“FULL” mark and an “ADD” mark. The fluid level must
be kept within these two marks. Do not add fluid above
the “FULL” mark, because leakage may occur at the cap.With disc brakes the fluid level can be expected to fall as
the brake linings wear. However, an unexpected drop in
fluid level may be caused by a leak and a system check
should be conducted.
Refer to “Fluids, Lubricants, and Genuine Parts” in this
section for the correct fluid type.
WARNING!
•
Use of a brake fluid that may have a lower initial
boiling point, or is unidentified as to specification,
may result in sudden brake failure during hard
prolonged braking. You could have an accident.
•
Overfilling the brake fluid reservoir can result in
spilling brake fluid on hot engine parts and the
brake fluid catching fire.
(Continued)
MAINTAINING YOUR VEHICLE 447
7

WARNING! (Continued)
•
Use only brake fluid that has been in a tightly-
closed container to avoid contamination from for-
eign matter or moisture.
CAUTION!
Do not allow a petroleum-base fluid to contaminate
the brake fluid. Seal damage may result.Rear Axle And 4x4 Front Driving Axle Fluid LevelFor normal service, periodic fluid level checks are not
required. When the vehicle is serviced for other reasons
the exterior surfaces of the axle assembly should be
inspected. If gear oil leakage is suspected inspect the
fluid level. Refer to “Fluids, Lubricants, and Genuine
Parts” in this section for the correct fluid type.This inspection should be made with the vehicle in a level
position. The fluid level should be even with the bottom
of the fill hole for the manufacturer’s C205F HD front
axles. The fluid level should be 5/8 in (16 mm) below the
fill hole on 9 1/4 in manufacturer’s rear axles.
For all 2500/3500 Model axles, the fluid level should be
1/4” ± 1/4 in (6.4 mm ± 6.4 mm) below the fill hole on
the 9.25 in front and 3/4 in ± 1/4 in (19 mm ± 6.4 mm) on
10.5 in rear axles. The 11.5 in rear axle level should be
1/4 in ± 1/4 in (6.4 mm ± 6.4 mm) below the fill hole.
Drain and RefillRefer to the “Maintenance Schedule” in Section 8 for the
proper maintenance intervals.Lubricant SelectionRefer to “Fluids, Lubricants, and Genuine Parts” in this
section for the correct fluid type.
448 MAINTAINING YOUR VEHICLE