recommended oil DODGE RAM 1500 1998 2.G Workshop Manual

²National Lubricating Grease Institute (NLGI)
API SERVICE GRADE CERTIFIED
Use an engine oil that is API Certified. MOPARt
provides engine oils, that meet or exceed this
requirement.
SAE VISCOSITY
An SAE viscosity grade is used to specify the vis-
cosity of engine oil. Use only engine oils with multi-
ple viscosities such as 5W-30 or 10W-30. These are
specified with a dual SAE viscosity grade which indi-
cates the cold-to-hot temperature viscosity range.
Select an engine oil that is best suited to your par-
ticular temperature range and variation (Fig. 1).
ENERGY CONSERVING OIL
An Energy Conserving type oil is recommended for
gasoline engines. The designation of ENERGY CON-
SERVING is located on the label of an engine oil con-
tainer.
CONTAINER IDENTIFICATION
Standard engine oil identification notations have
been adopted to aid in the proper selection of engine
oil. The identifying notations are located on the front
label of engine oil plastic bottles and the top of
engine oil cans (Fig. 2).
This symbol means that the oil has been certified
by the American Petroleum Institute (API). Diamler-
Chrysler only recommend API Certified engine oils.
Use Mopartengine oil or equivalent.
GEAR LUBRICANTS
SAE ratings also apply to multigrade gear lubri-
cants. In addition, API classification defines the
lubricants usage. Such as API GL-5 and SAE 75W-
90.
LUBRICANTS AND GREASES
Lubricating grease is rated for quality and usage
by the NLGI. All approved products have the NLGIsymbol (Fig. 3) on the label. At the bottom of the
NLGI symbol is the usage and quality identification
letters. Wheel bearing lubricant is identified by the
letter ªGº. Chassis lubricant is identified by the letter
ªLº. The letter following the usage letter indicates
the quality of the lubricant. The following symbols
indicate the highest quality.
SPECIALIZED LUBRICANTS AND OILS
Some maintenance or repair procedures may
require the use of specialized lubricants or oils. Con-
sult the appropriate sections in this manual for the
correct application of these lubricants.
DESCRIPTION - ENGINE OIL - DIESEL
ENGINES
Use only Diesel Engine Oil meeting standardMIL-
2104Cor API ClassificationCD or higherorCCML
D4, D5.
SAE VISCOSITY GRADE
CAUTION: Low viscosity oils must have the proper
API quality or the CCMC G5 designation. (Fig. 4)
To assure of properly formulated engine oils, it is
recommended that SAE Grade 10W-40 engine oils
that meet Chrysler material standard MS-6395, be
used in accordance to ACEA B3, B4 specification.
European Grade 10W-40 oils are also acceptable.
Fig. 1 TEMPERATURE/ENGINE OIL VISCOSITY
Fig. 2 API SYMBOL
Fig. 3 NLGI SYMBOL
1 - WHEEL BEARINGS
2 - CHASSIS LUBRICATION
3 - CHASSIS AND WHEEL BEARINGS
0 - 2 LUBRICATION & MAINTENANCEDR
FLUID TYPES (Continued)

Oils of the SAE 5W-40 grade number are preferred
when minimum temperatures consistently fall below
-15ÉC. (Fig. 5)
DESCRIPTION - POWER STEERING FLUID
MopartATF +4, Automatic Transmission Fluid is
required in the power steering system. Substitute
fluids can induce power steering system failure.
MopartATF +4, Automatic Transmission Fluid
when new is red in color. The ATF is dyed red so it
can be identified from other fluids used in the vehicle
such as engine oil or antifreeze. The red color is not
permanent and is not an indicator of fluid condition.
As the vehicle is driven, the ATF will begin to look
darker in color and may eventually become brown.
This is normal.ATF+4 also has a unique odor that
may change with age. Consequently, odor and color
cannot be used to indicate the fluid condition or the
need for a fluid change.
DESCRIPTION - ENGINE COOLANT
WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL
BASE COOLANT AND IS HARMFUL IF SWAL-
LOWED OR INHALED. IF SWALLOWED, DRINK
TWO GLASSES OF WATER AND INDUCE VOMIT-
ING. IF INHALED, MOVE TO FRESH AIR AREA.
SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT
STORE IN OPEN OR UNMARKED CONTAINERS.
WASH SKIN AND CLOTHING THOROUGHLY AFTER
COMING IN CONTACT WITH ETHYLENE GLYCOL.
KEEP OUT OF REACH OF CHILDREN. DISPOSE OF
GLYCOL BASE COOLANT PROPERLY, CONTACTYOUR DEALER OR GOVERNMENT AGENCY FOR
LOCATION OF COLLECTION CENTER IN YOUR
AREA. DO NOT OPEN A COOLING SYSTEM WHEN
THE ENGINE IS AT OPERATING TEMPERATURE OR
HOT UNDER PRESSURE, PERSONAL INJURY CAN
RESULT. AVOID RADIATOR COOLING FAN WHEN
ENGINE COMPARTMENT RELATED SERVICE IS
PERFORMED, PERSONAL INJURY CAN RESULT.
CAUTION: Use of Propylene Glycol based coolants
is not recommended, as they provide less freeze
protection and less corrosion protection.
The cooling system is designed around the coolant.
The coolant must accept heat from engine metal, in
the cylinder head area near the exhaust valves and
engine block. Then coolant carries the heat to the
radiator where the tube/fin radiator can transfer the
heat to the air.
The use of aluminum cylinder blocks, cylinder
heads, and water pumps requires special corrosion
protection. MopartAntifreeze/Coolant, 5
Year/100,000 Mile Formula (MS-9769), or the equiva-
lent ethylene glycol base coolant with organic corro-
sion inhibitors (called HOAT, for Hybrid Organic
Additive Technology) is recommended. This coolant
offers the best engine cooling without corrosion when
mixed with 50% Ethylene Glycol and 50% distilled
water to obtain a freeze point of -37ÉC (-35ÉF). If it
loses color or becomes contaminated, drain, flush,
and replace with fresh properly mixed coolant solu-
tion.
CAUTION: MoparTAntifreeze/Coolant, 5
Year/100,000 Mile Formula (MS-9769) may not be
mixed with any other type of antifreeze. Mixing of
coolants other than specified (non-HOAT or other
HOAT), may result in engine damage that may not
be covered under the new vehicle warranty, and
decreased corrosion protection.
COOLANT PERFORMANCE
The required ethylene-glycol (antifreeze) and water
mixture depends upon climate and vehicle operating
conditions. The coolant performance of various mix-
tures follows:
Pure Water-Water can absorb more heat than a
mixture of water and ethylene-glycol. This is for pur-
pose of heat transfer only. Water also freezes at a
higher temperature and allows corrosion.
100 percent Ethylene-Glycol-The corrosion
inhibiting additives in ethylene-glycol need the pres-
ence of water to dissolve. Without water, additives
form deposits in system. These act as insulation
causing temperature to rise to as high as 149ÉC
(300ÉF). This temperature is hot enough to melt plas-
Fig. 4 API RATING WRAP FIGURE
Fig. 5 DIESEL OIL VISCOSITY CHART
DRLUBRICATION & MAINTENANCE 0 - 3
FLUID TYPES (Continued)

tic and soften solder. The increased temperature can
result in engine detonation. In addition, 100 percent
ethylene-glycol freezes at -22ÉC (-8ÉF).
50/50 Ethylene-Glycol and Water-Is the recom-
mended mixture, it provides protection against freez-
ing to -37ÉC (-34ÉF). The antifreeze concentration
must alwaysbe a minimum of 44 percent, year-
round in all climates. If percentage is lower, engine
parts may be eroded by cavitation. Maximum protec-
tion against freezing is provided with a 68 percent
antifreeze concentration, which prevents freezing
down to -67.7ÉC (-90ÉF). A higher percentage will
freeze at a warmer temperature. Also, a higher per-
centage of antifreeze can cause the engine to over-
heat because specific heat of antifreeze is lower than
that of water.
CAUTION: Richer antifreeze mixtures cannot be
measured with normal field equipment and can
cause problems associated with 100 percent ethyl-
ene-glycol.
COOLANT SELECTION AND ADDITIVES
NOTE: Refer to the vehicle's coolant bottle to iden-
tify HOAT or Non-HOAT coolant. Non-HOAT coolant
is green in color.
The use of aluminum cylinder blocks, cylinder
heads and water pumps requires special corrosion
protection. Only MopartAntifreeze/Coolant, 5
Year/100,000 Mile Formula (glycol base coolant with
corrosion inhibitors called HOAT, for Hybrid Organic
Additive Technology) is recommended. This coolant
offers the best engine cooling without corrosion when
mixed with 50% distilled water to obtain to obtain a
freeze point of -37ÉC (-35ÉF). If it loses color or
becomes contaminated, drain, flush, and replace with
fresh properly mixed coolant solution.
CAUTION: Do not use coolant additives that are
claimed to improve engine cooling.
DESCRIPTION - TRANSFER CASE
Recommended lubricant for the NV241 GENII,
NV271, NV243, NV244 GENII, and NV273 transfer
cases is MopartATF +4, Automatic Transmission
Fluid.
DESCRIPTION - AXLE
NOTE: DaimlerChrysler recommends using MoparT
lubricants or lubricants of equal quality.
FRONT AXLE
²C205F - MopartGear Lubricant 75W-90
²9 1/4 AA - MopartSynthetic Gear Lubricant
75W-90
REAR AXLE
²9 1/4 - MopartSynthetic Gear Lubricant 75W-
140
²10 1/2 AA - MopartSynthetic Gear Lubricant
75W-90
²11 1/2 AA - MopartSynthetic Gear Lubricant
75W-90
NOTE: Trac-LokTdifferentials require Limited Slip
Additive in the lubricant. Trac-RiteŸ differentials
DO NOT require Limited Slip Additive.
DESCRIPTION - MANUAL TRANSMISSION
NOTE: DaimlerChrysler recommends using MoparT
lubricants or lubricants of equal quality.
²NV3500 - MopartManual Transmission Lubri-
cant
²NV4500 - MopartSynthetic 75W85 Manual
Transmission Lubricant
²NV5600 - MopartManual Transmission Lubri-
cant
DESCRIPTION - AUTOMATIC TRANSMISSION
FLUID
NOTE: Refer to Service Procedures in this group for
fluid level checking procedures.
MopartATF +4, Automatic Transmission Fluid is
the recommended fluid for DaimlerChrysler auto-
matic transmissions.
Dexron II fluid IS NOT recommended. Clutch
chatter can result from the use of improper
fluid.
MopartATF +4, Automatic Transmission Fluid
when new is red in color. The ATF is dyed red so it
can be identified from other fluids used in the vehicle
such as engine oil or antifreeze. The red color is not
permanent and is not an indicator of fluid condition.
As the vehicle is driven, the ATF will begin to look
darker in color and may eventually become brown.
This is normal.ATF+4 also has a unique odor that
may change with age. Consequently, odor and color
cannot be used to indicate the fluid condition or the
need for a fluid change.
0 - 4 LUBRICATION & MAINTENANCEDR
FLUID TYPES (Continued)

Miles 105,000 108,000 111,000 114,000 117,000 120,000
(Kilometers) (168 000) (173 000) (178 000) (182 000) (187 000) (192 000)
Change engine oil and engine
oil filter.XXXXX X
Lubricate outer tie rod ends
2500/3500 (4X4) models only.XXX
Drain and refill transfer case
fluid (4X4).X
Change rear axle fluid. X X
Change front axle fluid (4X4). X X
Inspect brake linings. X X
Inspect engine air cleaner
filter, replace if necessary.XX
Replace spark plugs.X
Replace ignition cables.X
Inspect PCV valve, replace
as necessary.X*
Inspect auto tension drive belt
and replace if required
(3.7L/4.7L/5.7L).X³ X³
Drain and refill automatic
tranmission fluid and change
main sump filter (45RFE/
545RFE only).X
* This maintenance is recommended by the manu-
facture to the owner but is not required to maintain
the emissions warranty.
³ This maintenance is not required if previously
replaced.Inspection and service should also be performed
anytime a malfunction is observed or suspected.
Retain all receipts.
Schedule ªAº
Miles 6,000 12,000 18,000 24,000 30,000
(Kilometers) (10 000) (19 000) (29 000) (38 000) (48 000)
[Months] [6] [12] [18] [24] [30]
Change engine oil and engine oil filter.XXXX X
Check transfer case fluid level (4X4). X
Lubricate outer tie rod ends 2500/3500
(4X4) models only.XXXX X
Inspect brake linings. X
Replace engine air cleaner filter.X
Replace spark plugs.X
0 - 10 LUBRICATION & MAINTENANCEDR
MAINTENANCE SCHEDULES (Continued)

Miles 102,000 108,000 114,000 120,000
(Kilometers) (163 000) (173 000) (182 000) (192 000)
[Months] [102] [108] [114] [120]
Change engine oil and engine oil filter. X X X X
Drain and refill transfer case fluid (4X4). X
Flush and replace engine coolant, if not done at 60 mos. X
Lubricate outer tie rod ends 2500/3500 (4X4) models
only.XXX X
Inspect brake linings. X
Inspect auto tension drive belt and replace if required
(3.7L/4.7L/5.7L).X³X³
Replace ignition cables.X
Replace engine air cleaner filter.X
Replace spark plugs.X
Inspect PCV Valve, replace as necessary X*
* This maintenance is recommended by the manu-
facture to the owner but is not required to maintain
the emissions warranty.
³ This maintenance is not required if previously
replaced.
Inspection and service should also be performed
anytime a malfunction is observed or suspected.
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 right
equipment. If you have any doubt about your ability
to perform a service job, take your vehicle to a
competent mechanic.
MAINTENANCE SCHEDULES Ð 24±VALVE
CUMMINS TURBO DIESEL
There are two maintenance schedules that show
therequiredservice for your vehicle.
First is ScheduleªBº. It is for vehicles that are
operated under the conditions that are listed below
and at the beginning of the schedule.
²Day or night temperatures are below 0É C (32É
F).
²Stop and go driving.
²Extensive engine idling.
²Driving in dusty conditions.
²Short trips of less than 16 km (10 miles).
²More than 50% of your driving is at sustained
high speeds during hot weather, above 32É C (90É F).²Trailer towing.
²Taxi, police, or delivery service (commercial ser-
vice).
²Off-road or desert operation.
NOTE: Most vehicles are operated under the condi-
tions listed for Schedule(B(.
Second is ScheduleªAº. It is for vehicles that are
not operated under any of the conditions listed under
Schedule9B9.
Use the schedule that best describes your driving
conditions. Where time and mileage are listed, follow
the interval that occurs first.
CAUTION: Failure to perform the required mainte-
nance items may result in damage to the vehicle.At Each Stop for Fuel
²Check the engine oil level about 15 minutes
after a fully warmed engine is shut off. Checking the
oil level while the vehicle is on level ground will
improve the accuracy of the oil level reading. Add oil
only when the level is at or below the ADD or MIN
mark.
²Check the windshield washer solvent and add if
required.
²Drain water from the fuel filter.
0 - 12 LUBRICATION & MAINTENANCEDR
MAINTENANCE SCHEDULES (Continued)

A wooden crossbeam may be required for proper
connection when using the sling-type, front-end tow-
ing method.
SAFETY PRECAUTIONS
CAUTION: The following safety precautions must be
observed when towing a vehicle:
²Secure loose and protruding parts.
²Always use a safety chain system that is inde-
pendent of the lifting and towing equipment.
²Do not allow towing equipment to contact the
disabled vehicle's fuel tank.
²Do not allow anyone under the disabled vehicle
while it is lifted by the towing device.
²Do not allow passengers to ride in a vehicle
being towed.
²Always observe state and local laws regarding
towing regulations.
²Do not tow a vehicle in a manner that could
jeopardize the safety of the operator, pedestrians or
other motorists.
²Do not attach tow chains, T-hooks, J-hooks, or a
tow sling to a bumper, steering linkage, drive shafts
or a non-reinforced frame hole.
²Do not tow a heavily loaded vehicle. Damage to
the cab, cargo box or frame may result. Use a flatbed
device to transport a loaded vehicle.
GROUND CLEARANCE
CAUTION: If vehicle is towed with wheels removed,
install lug nuts to retain brake drums or rotors.
A towed vehicle should be raised until lifted wheels
are a minimum 100 mm (4 in) from the ground. Be
sure there is adequate ground clearance at the oppo-
site end of the vehicle, especially when towing over
rough terrain or steep rises in the road. If necessary,remove the wheels from the lifted end of the vehicle
and lower the vehicle closer to the ground, to
increase the ground clearance at the opposite end of
the vehicle. Install lug nuts on wheel attaching studs
to retain brake drums or rotors.
RAMP ANGLE
If a vehicle with flat-bed towing equipment is used,
the approach ramp angle should not exceed 15
degrees.
TOWING WHEN KEYS ARE NOT AVAILABLE
When the vehicle is locked and keys are not avail-
able, use a flat bed hauler. A Wheel-lift or Sling-type
device can be used on 4WD vehicles providedall the
wheels are lifted off the ground using tow dol-
lies.
FOUR-WHEEL-DRIVE VEHICLE TOWING
Chrysler Corporation recommends that a vehicle be
transported on a flat-bed device. A Wheel-lift or
Sling-type device can be used providedall the
wheels are lifted off the ground using tow dol-
lies.
WARNING: WHEN TOWING A DISABLED VEHICLE
AND THE DRIVE WHEELS ARE SECURED IN A
WHEEL LIFT OR TOW DOLLIES, ENSURE THE
TRANSMISSION IS IN THE PARK POSITION (AUTO-
MATIC TRANSMISSION) OR A FORWARD DRIVE
GEAR (MANUAL TRANSMISSION).
CAUTION: Many vehicles are equipped with air
dams, spoilers, and/or ground effect panels. To
avoid component damage, a wheel-lift towing vehi-
cle or a flat-bed hauling vehicle is recommended.
0 - 22 LUBRICATION & MAINTENANCEDR
TOWING (Continued)

(3) Install parking brake cable in the brake lever.
(4) Install the park brake shoes (Refer to 5 -
BRAKES/PARKING BRAKE/SHOES - INSTALLA-
TION). (Fig. 66).
(5) Install axle shaft, (Refer to 3 - DIFFEREN-
TIAL & DRIVELINE/REAR AXLE - 9 1/4/AXLE
SHAFTS - INSTALLATION).
(6) Adjust brake shoes to drum with brake gauge
(Refer to 5 - BRAKES/PARKING BRAKE/SHOES -
ADJUSTMENTS).
(7) Install the rotor (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/ROTORS - INSTALLA-
TION).
(8) Install the caliper adapter (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPER ADAPTER - INSTALLATION).
(9) Install the caliper (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/DISC BRAKE CALIPERS
- INSTALLATION).
(10) Install wheel and tire assembly.
FLUID
DIAGNOSIS AND TESTING - BRAKE FLUID
CONTAMINATION
Indications of fluid contamination are swollen or
deteriorated rubber parts.
Swollen rubber parts indicate the presence of
petroleum in the brake fluid.
To test for contamination, put a small amount of
drained brake fluid in clear glass jar. If fluid sepa-
rates into layers, there is mineral oil or other fluid
contamination of the brake fluid.
If brake fluid is contaminated, drain and thor-
oughly flush system. Replace master cylinder, propor-
tioning valve, caliper seals, wheel cylinder seals,
Antilock Brakes hydraulic unit and all hydraulic
fluid hoses.
STANDARD PROCEDURE - BRAKE FLUID
LEVEL
Always clean the master cylinder reservoir and
caps before checking fluid level. If not cleaned, dirt
could enter the fluid.
The fluid fill level is indicated on the side of the
master cylinder reservoir (Fig. 41).
The correct fluid level is to the MAX indicator on
the side of the reservoir. If necessary, add fluid to the
proper level.
SPECIFICATIONS
BRAKE FLUID
The brake fluid used in this vehicle must conform
to DOT 3 specifications and SAE J1703 standards.
No other type of brake fluid is recommended or
approved for usage in the vehicle brake system. Use
only Mopar brake fluid or an equivalent from a
tightly sealed container.
CAUTION: Never use reclaimed brake fluid or fluid
from an container which has been left open. An
open container of brake fluid will absorb moisture
from the air and contaminate the fluid.
CAUTION: Never use any type of a petroleum-based
fluid in the brake hydraulic system. Use of such
type fluids will result in seal damage of the vehicle
brake hydraulic system causing a failure of the
vehicle brake system. Petroleum based fluids would
be items such as engine oil, transmission fluid,
power steering fluid, etc.
FLUID RESERVOIR
REMOVAL
(1) Install the prop rod on the brake pedal to keep
pressure on the brake system.
(2) Remove the reservoir cap and siphon fluid into
a drain container (Fig. 42).
(3) Remove the electrical connector from the fluid
level switch in the reservoir (Fig. 42).
(4) Remove the reservoir mounting bolt (Fig. 42).
Fig. 41 FLUID LEVEL TYPICAL
1 - FLUID RESERVOIR
2 - MAX LEVEL MARK
DRBRAKES - BASE 5 - 23
DISC BRAKE CALIPER ADAPTER MOUNT (Continued)

CLUTCH
TABLE OF CONTENTS
page page
CLUTCH
WARNING.............................1
DIAGNOSIS AND TESTING................1
SPECIFICATIONS........................5
CLUTCH DISC
REMOVAL.............................5
INSTALLATION..........................5
CLUTCH HOUSING
DIAGNOSIS AND TESTING................7
REMOVAL.............................9
INSTALLATION..........................9
CLUTCH RELEASE BEARING
REMOVAL.............................9
INSTALLATION.........................10
FLYWHEEL
DIAGNOSIS AND TESTING................10REMOVAL.............................11
DISASSEMBLY.........................11
ASSEMBLY............................11
INSTALLATION.........................11
PILOT BEARING
REMOVAL.............................11
INSTALLATION.........................12
LINKAGE
REMOVAL.............................12
INSTALLATION.........................12
CLUTCH PEDAL POSITION SWITCH
DESCRIPTION.........................13
OPERATION...........................13
DIAGNOSIS AND TESTING................13
CLUTCH
WARNING
WARNING: Exercise care when servicing clutch
components. Factory installed clutch discs do not
contain asbestos fibers. Dust and dirt on clutch
parts may contain asbestos fibers from aftermarket
components. Breathing excessive concentrations of
these fibers can cause serious bodily harm. Wear a
respirator during service and never clean clutch
components with compressed air or with a dry
brush. Either clean the components with water
dampened rags or use a vacuum cleaner specifi-
cally designed to remove asbestos fibers and dust.
Do not create dust by sanding a clutch discs.
Replace the disc if the friction material is damaged.
Dispose of all dust and dirt containing asbestos
fibers in sealed bags or containers. This will mini-
mize exposure to yourself and to others. Follow all
recommended safety practices prescribed by the
occupational safety and health administration
(OSHA) and the environmental safety agency (EPA),
for the handling and disposal of products contain-
ing asbestos. Failure to follow these instructions
may result in personal injury or death
DIAGNOSIS AND TESTING
Road test and inspect components to determine a
clutch problem. Road test the vehicle at normalspeeds. Shift the transmission through all gear
ranges and observe clutch action. If clutch chatters,
grabs, slips or does not release properly, remove and
inspect clutch components. If problem is noise or
hard shifting, further diagnosis may be needed to the
transmission and driveline component.
CLUTCH CONTAMINATION
Contamination is a frequent cause of clutch mal-
functions. Oil, water or clutch fluid on the clutch disc
and pressure plate surfaces will cause chatter, slip
and grab. Oil contamination indicates a leak at
either the rear main seal or transmission input shaft.
Clutch fluid leaks are usually from damaged slave
cylinder push rod seals. Heat buildup caused by slip-
page between the pressure plate, disc and flywheel
can bake the oil residue onto the components. The
glaze-like residue ranges in color from amber to
black.
Road splash contamination is dirt/water entering
the clutch housing due to loose bolts, housing cracks.
Driving through deep water puddles can force water/
road splash into the housing through such openings.
IMPROPER RELEASE OR CLUTCH ENGAGEMENT
Clutch release or engagement problems can be
caused by worn or damage clutch components.
Release problems can cause hard shifting and
noise. Look for leaks at clutch cylinders, connecting
line and loose slave cylinder bolts. Also worn/loose
release fork, pivot stud, clutch disc, pressure plate or
release bearing.
DRCLUTCH 6 - 1

STANDARD PROCEDURE - REFILLING
COOLING SYSTEM 5.9L DIESEL ENGINE
Clean cooling system prior to refilling (Refer to 7 -
COOLING - STANDARD PROCEDURE).
(1) Close radiator drain plug.
CAUTION: Due to the use of the one-way check
valve, the engine must not be operating when refill-
ing the cooling system.
NOTE: The diesel engine is equipped with two one-
way check valves (jiggle pins). The check valves
are used as a servicing feature and will vent air
when the system is being filled. Water pressure (or
flow) will hold the valves closed.
(2) Fill the cooling system with a 50/50 mixture of
water and antifreeze.
(3) Fill coolant reserve/overflow tank to the FULL
mark.
(4) Start and operate engine until thermostat
opens. Upper radiator hose should be warm to touch.
(5) If necessary, add 50/50 water and antifreeze
mixture to the coolant reserve/overflow tank to main-
tain coolant level. This level should be between the
ADD and FULL marks. The level in the reserve/over-
flow tank may drop below the ADD mark after three
or four warm-up and cool-down cycles.
STANDARD PROCEDURE - ADDING
ADDITIONAL COOLANT
The use of aluminum cylinder blocks, cylinder
heads and water pumps requires special corrosion
protection. Only MopartAntifreeze/Coolant, 5
Year/100,000 Mile Formula (glycol base coolant with
corrosion inhibitors called HOAT, for Hybrid Organic
Additive Technology) is recommended. This coolant
offers the best engine cooling without corrosion when
mixed with 50% distilled water to obtain a freeze
point of -37ÉC (-35ÉF). If it loses color or becomes con-
taminated, drain, flush, and replace with fresh prop-
erly mixed coolant solution.
CAUTION: Do not use coolant additives that are
claimed to improve engine cooling.
Do not remove the radiator cap to add coolant to
the system. When adding coolant to maintain the cor-
rect level, do so only at the reserve/overflow bottle.
Remove the radiator cap only for testing or when
refilling the system after service. Removing the cap
unnecessarily can cause loss of coolant and allow air
to enter the system, which produces corrosion.
WARNING: DO NOT REMOVE OR LOOSEN THE
RADIATOR CAP WITH THE COOLING SYSTEM HOTAND UNDER PRESSURE. SERIOUS BURNS FROM
THE COOLANT OR HIGH PRESSURE STEAM CAN
OCCUR.
SPECIFICATIONS
TORQUE
DESCRIPTION N´m Ft.
Lbs.In.
Lbs.
Bolt - Automatic Belt
Tensioner to Block41 30 -
Bolt - Automatic Belt
Tensioner Pulley61 45 -
Bolt - Automatic Belt
Tensioner Pulley - Diesel43 32 -
Bolt - Block Heater 2 - 17
Bolts - Generator/
Compressor Mounting
Bracket
# 1 and 2 54 40 -
# 3 40 30 -
Bolts - Generator/
Compressor Mounting
Bracket - Diesel24 18 -
Bolts - Fan Shroud to
Radiator Mounting - All
Except 5.9L Diesel6-55
5.9L Diesel 11.8 - 105
Bolts - Radiator to Support 8.5 - 75
Bolts - Fan Blade to
Viscous Fan Drive24 18 -
Fan Drive - All Except
8.0L/5.9L Diesel50 37 -
8.0L/5.9L Diesel 115 85 -
Bolt - Idler Pulley 54 40 -
Bolt - Idler Pulley - Diesel 43 32 -
Bolts - Thermostat Housing
- All Except 5.9L13 - 112
Bolts - Thermostat Housing
5.9L23 16 -
Bolts - Thermostat Housing
- Diesel10 - 89
Bolts - Power Steering Oil
Cooler8.4 - 75
Bolts - Transmission
Auxiliary Oil Cooler6-55
DRCOOLING 7 - 19
COOLING (Continued)

DIAGNOSIS AND TESTING - RADIATOR
CAP................................58
CLEANING............................59
INSPECTION..........................59
WATER PUMP - 3.7L/4.7L
DESCRIPTION
DESCRIPTION - WATER PUMP...........59
DESCRIPTION - WATER PUMP BYPASS....59
OPERATION
OPERATIONÐWATER PUMP............60
OPERATION - WATER PUMP BYPASS.....60
REMOVAL.............................60
CLEANING............................61
INSPECTION..........................61
INSTALLATION.........................61
WATER PUMP - 5.9L DIESEL
DESCRIPTION.........................62OPERATION...........................62
DIAGNOSIS AND TESTINGÐWATER PUMP . . . 62
REMOVAL.............................62
CLEANING............................62
INSPECTION..........................62
INSTALLATION.........................62
WATER PUMP - 5.7L
REMOVAL.............................63
INSTALLATION.........................63
WATER PUMP - 8.0L
DIAGNOSIS AND TESTING - WATER PUMP . . . 63
REMOVAL.............................64
CLEANING............................66
INSPECTION..........................66
INSTALLATION.........................66
COOLANT
DESCRIPTION
DESCRIPTION - ENGINE COOLANT
ETHYLENE-GLYCOL MIXTURES
CAUTION: Richer antifreeze mixtures cannot be
measured with normal field equipment and can
cause problems associated with 100 percent ethyl-
ene-glycol.
The use of aluminum cylinder blocks, cylinder
heads and water pumps requires special corrosion
protection. Only MopartAntifreeze/Coolant, 5
year/100,000 Mile Formula (ethylene-glycol base cool-
ant with corrosion inhibitors called HOAT, for Hybrid
Additive Technology) is recommended. This coolant
offers the best engine cooling without corrosion when
mixed with 50% distilled water to obtain a freeze
point of -37ÉC (-35ÉF).
The required ethylene-glycol (antifreeze) and water
mixture depends upon the climate and vehicle oper-
ating conditions. The antifreeze concentrationmust
alwaysbe a minimum of 44 percent, year-round in
all climates.If percentage is lower than 44 per-
cent, engine parts may be eroded by cavitation,
and cooling system components may be
severely damaged by corrosion.Maximum protec-
tion against freezing is provided with a 68% anti-
freeze concentration, which prevents freezing down to
-67.7É C (-90É F). A higher percentage will freeze at a
warmer temperature. Also, a higher percentage of
antifreeze can cause the engine to overheat becausethe specific heat of antifreeze is lower than that of
water.
Use of 100 percent ethylene-glycol will cause for-
mation of additive deposits in the system, as the cor-
rosion inhibitive additives in ethylene-glycol require
the presence of water to dissolve. The deposits act as
insulation, causing temperatures to rise to as high as
149É C (300É F). This temperature is hot enough to
melt plastic and soften solder. The increased temper-
ature can result in engine detonation. In addition,
100 percent ethylene-glycol freezes at 22É C (-8É F ).
PROPYLENE-GLYCOL MIXTURES
It's overall effective temperature range is smaller
than that of ethylene-glycol. The freeze point of 50/50
propylene-glycol and water is -32É C (-26É F). 5É C
higher than ethylene-glycol's freeze point. The boiling
point (protection against summer boil-over) of propy-
lene-glycol is 125É C (257ÉF)at96.5 kPa (14 psi),
compared to 128É C (263É F) for ethylene-glycol. Use
of propylene-glycol can result in boil-over or freeze-up
on a cooling system designed for ethylene-glycol. Pro-
pylene glycol also has poorer heat transfer character-
istics than ethylene glycol. This can increase cylinder
head temperatures under certain conditions.
Propylene-glycol/ethylene-glycol Mixtures can
cause the destabilization of various corrosion inhibi-
tors, causing damage to the various cooling system
components. Also, once ethylene-glycol and propy-
lene-glycol based coolants are mixed in the vehicle,
conventional methods of determining freeze point will
not be accurate. Both the refractive index and spe-
cific gravity differ between ethylene glycol and propy-
lene glycol.
DRENGINE 7 - 31