engine RAM CHASSIS CAB 2007 Owners Manual

MAINTAINING YOUR VEHICLECONTENTS
Engine Compartment — 6.7L Diesel Engine ....392

Engine Compartment— 5.7L Gas Engine ......393

Onboard Diagnostic System (OBD II) .........394
▫ Loose Fuel Filler Cap Message ............394

Replacement Parts ......................395

Engine Data Plate ......................395

Dealer Service .........................395

Service Information .....................396

Maintenance Procedures ..................398 ▫ Engine Oil ..........................398
▫ Drive Belts (Gas Engines) ...............406
▫ Drive Belt (Diesel Engines) ..............406
▫ Engine Air Cleaner Filter (Gas Engines) .....406
▫ Engine Air Cleaner Filter (Diesel Engines) ....407
▫ Draining Fuel/Water Separator Filter (Diesel
Engines) ............................410
▫ Engine Fuel Filter (Gas Engines) ...........413
▫ Spark Plugs (Gas Engines) ...............413
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▫ Catalytic Converter (Gas Engines) .........413
▫ Intervention Regeneration Strategy – EVIC
Message Process Flow (Catalyst Full Message)
(Diesel Engines Only) ..................415
▫ Emission-Related Components (Gas Engines) . . 418
▫ Maintenance Free Battery (Gas Engines) .....418
▫ Maintenance Free Batteries (Diesel Engines) . . . 419
▫ Air Conditioner Maintenance .............420
▫ Power Steering — Fluid Check ............421
▫ Front Suspension Ball Joints ..............422
▫ Steering Linkage — Inspection ............422
▫ Front Prop Shaft Lubrication .............422
▫ Front Axle Universal Drive Joints And Pivot
Bearings ............................423 ▫ Body Lubrication .....................423
▫ Windshield Wiper Blades ................424
▫ Windshield Washers ...................424
▫ Exhaust System ......................425
▫ Cooling System .......................426
▫ Fan ...............................432
▫ Charge Air Cooler — Inter-Cooler (Diesel
Engines) ............................432
▫ Hoses And Vacuum/Vapor Harnesses .......433
▫ Fuel System Connections ................433
▫ Brake System ........................434
▫ Clutch Hydraulic System ................436
▫ Clutch Linkage .......................436390 MAINTAINING YOUR VEHICLE

▫ Rear Axle And 4X4 Front Driving Axle Fluid
Level ..............................436
▫ Transfer Case — If Equipped .............437
▫ Manual Transmission — If Equipped .......438
▫ Automatic Transmission (Gas Engine Only) . . . 438
▫ Automatic Transmission (Diesel Engine Only) . 441
▫ Front And Rear Wheel Bearings ...........444
▫ Noise Control System Required Maintenance &
Warranty ...........................445
▫ Appearance Care And Protection From
Corrosion ...........................452

Fuses (Integrated Power Module) ...........457
Vehicle Storage ........................461

Replacement Light Bulbs .................461

Bulb Replacement ......................462
▫ Headlight (Halogen)/Front Park And
TurnLights .........................462
▫ Fog Lights ..........................465
▫ Cab Top Clearance Lights — If Equipped ....466

Fluid And Capacities ....................468

Fluids, Lubricants And Genuine Parts ........469
▫ Engine .............................469
▫ Chassis ............................471 MAINTAINING YOUR VEHICLE 391
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ENGINE COMPARTMENT — 6.7L DIESEL ENGINE 392 MAINTAINING YOUR VEHICLE

ENGINE COMPARTMENT— 5.7L GAS ENGINE MAINTAINING YOUR VEHICLE 393
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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 emis-
sion 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.
Loose Fuel Filler Cap Message
If the vehicles diagnostic system determines that the fuel
filler cap in loose, improperly installed, or damaged, a
GASCAP message will be displayed in the instrument
cluster. Tighten the gas cap until a “clicking” sound is
heard. This is an indication that the gas cap is properly
tightened. Press the odometer reset button to turn the394 MAINTAINING YOUR VEHICLE

message off. If the problem persists, the message will
appear the next time the vehicle is started. This might
indicate a damaged cap. If the problem is detected twice
in a row, the system will turn on the Malfunction
Indicator Light (MIL). Resolving the problem will turn
the MIL light off.
REPLACEMENT PARTS
Use of genuine Mopar  parts for normal/scheduled
maintenance and repairs is highly recommended to in-
sure the designed performance. Damage or failures
caused by the use of non-Mopar parts for maintenance
and repairs will not be covered by the manufacturer’s
warranty. 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.
DEALER SERVICE
Your dealer 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 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. MAINTAINING YOUR VEHICLE 395
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NOTE: It is not possible for the manufacturer and
Cummins, Inc. to anticipate every possible circumstance
that can involve a potential hazard.
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. MAINTAINING YOUR VEHICLE 397
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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.
• Important: All maintenance other than that listed in
this manual, as well as some procedures listed here,
MUST be performed by your local Dodge Truck
Dealer. Your authorized Dodge Dealer has been
trained and has the necessary parts to maintain your
engine. 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.
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 the398 MAINTAINING YOUR VEHICLE

engine, first ensure the engine is at full operating tem-
perature, then wait at least 15 minutes after engine
shutdown to check the oil.
Checking the oil while the vehicle is on level ground will
improve the accuracy of the oil level readings. Always
maintain the oil level within the SAFE zone on the
dipstick. Adding one quart of oil when the reading is at
the bottom of the SAFE zone will result in a reading at the
top of the safe zone on these engines.
CAUTION!Overfilling or underfilling the crankcase will cause
oil aeration or loss of oil pressure. This could dam-
age your engine. Never operate the engine with oil level below the “ADD”
mark or above the upper “SAFE” mark. MAINTAINING YOUR VEHICLE 399
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