DODGE RAM 2001 Service Repair Manual

Check windshield washer solvent reservoir and fill
as necessary (Fig. 6).
NOTE: When using concentrated solvent such as
MoparTAll-Weather Windshield Washer Solution,
dilute per container directions.
COOLING SYSTEM RESERVOIR
WARNING: DO NOT REMOVE RADIATOR CAP
WHILE COOLING SYSTEM IS UNDER PRESSURE.
NOTE: Add coolant only to plastic reserve tank if it is
required. Engine must be at normal operating temper-
ature before adding coolant to reserve tank. In cold
climates, coolant in reserve tank may appear low; do
not add coolant until normal temperature is reached.
Check coolant level with engine idling at normal
operating temperature. Coolant level in plastic
reserve tank must be between the minimum and
maximun marks (Fig. 7).
If coolant is added, use a 50/50 (-309F protection) con-
centration of the recommended (Refer to the Service
Information for specificate Mopartantifreeze recom-
mendation ) antifreeze and distilled water. Use a
higher concentration (up to 65%) if a lower freeze point
is required. Do not use recycled coolant in new vehicles.
INSPECTION - LINES/HOSES
Inspect the following for line and hose leaks. Also
inspect routing and connections and reroute and
tighten as required.²Brake Lines (Fig. 8)
²Fuel Lines (Fig. 9)
²Power Steering Hoses
²Vacuum Hoses
²Heating/Coolant Hoses
²Clutch Lines
²Refrigerant Lines
²Transmission oil cooler lines (Fig. 10)
Fig. 7 ENGINE COOLANT RESERVOIRFig. 8 PARKING BRAKE CABLE AND BRAKE LINE
Fig. 9 BRAKE LINES AND FUEL LINES
1 - FUEL LINE
2 - BRAKE LINE
30 - 6 NEW VEHICLE PREPARATIONBR/BE
UNDER HOOD (Continued)

INSPECTION - BATTERY
When battery is easily accessible, check the test
indicator (green dot), terminal tightness and felt
(grease) washer on battery posts. Recharge battery as
required to assure that the green dot is visible.
When battery is not easily accessible check battery
condition with a voltmeter at the jump start loca-
tions, or check the voltmeter on the instrument panel
(Fig. 11) or (Fig. 12). The reading should be at least
12.4 volts. Recharge battery as required.
NOTE: Refer to service information for proper bat-
tery charging rates and times.
INSPECTION - WIRING
The assembly plant has shipped all vehicles with
the interior lights and most electronic memories non-
functional by way of an Ignition Off Draw (IOD) fuse
removed. The purpose is to reduce the possibility of
battery run-down during shipping and storage.
Vehicles stored after prep should have the IOD
fuse that activates the accessories pulled to prevent
battery drain.
NOTE: Ensure that the IOD fuse is removed to pre-
vent battery drain and possible damage. Vehicles
stored for extended periods after prep should be
washed frequently, to prevent environmental dam-age, and reinspected for storage-related problems
before delivery.
(1) Install the IOD fuse as equipped. (ON vehicles
being delivered, remember to reset radio, clock, com-
pass, etc., as required.)
(2) Check routing and connections of all underhood
wiring-reroute and connect as required.
(3) Make sure the starter, generator and air condi-
tioning clutch wiring are correctly installed, routed,
and in the clips where provided.
(4) For predelivery storage, always pull the IOD
fuse that activates accessories.
Fig. 10 TRANSMISSION COOLER LINES AND
RADIATOR HOSE
1 - TRANSMISSION OIL COOLER LINES
2 - RADIATOR LOWER HOSE
Fig. 11 BATTERY VOLTAGE GAUGE DIESEL ENGINE
Fig. 12 BATTERY VOLTAGE GAUGE GAS ENGINE
BR/BENEW VEHICLE PREPARATION 30 - 7
UNDER HOOD (Continued)

UNDER VEHICLE
INSPECTION - TIRE PRESSURES
(1) Using the tire placard or the Safety Certifica-
tion Label, check that the correct tires are mounted
on the vehicle.
(2) Install valve stem extensions as required.
(3) Using the tire placard or the Safety Certifica-
tion Label, check tire pressure (including spare) and
adjust as required to recommended pressure.
(4) Inspect the spare tire for correct pressure and
proper mounting (Fig. 13).
NOTE: Tire pressure may have been set above nor-
mal during manufacturing in order to properly seat
the tire bead. Be sure to adjust to proper specifica-
tion.
INSPECTION - VISUAL
CAUTION: Before raising the vehicle on a hoist,
(Refer to LUBRICATION & MAINTENANCE/HOISTING
- STANDARD PROCEDURE) for the proper lifting
points.
(1) Visually inspect the following for loose attach-
ment, leakage, clearance and routing, and tighten
connections and clamps as required:
²Engine
²Oil Cooler
²Cooling System
²Transmission
²Driveshaft Boots²Differential
²Transfer Case (Fig. 19)
²Transmission Cooler and Lines (Fig. 18)
²Brake System and Lines (Fig. 14)
²Fuel System
²Exhaust System (Fig. 15), (Fig. 16) and (Fig. 17)
²Steering and Suspension Components
Fig. 13 SPARE TIRE INSPECTION
Fig. 14 BRAKE LINES TO CALIPERS (REAR)
Fig. 15 EXHAUST CLAMPS
30 - 8 NEW VEHICLE PREPARATIONBR/BE

Fig. 16 EXHAUST HANGERS
Fig. 17 TAILPIPE HANGERS
Fig. 18 TRANSMISSION COOLER LINES
Fig. 19 TRANSFER CASE INSPECTION
BR/BENEW VEHICLE PREPARATION 30 - 9
UNDER VEHICLE (Continued)

INSTALLATION - WHEEL COVERS
(1) Install cover on wheel by hand only (Fig. 20).
(2) Install and torque wheel nuts to 135 N´m (100
lb. ft.).
(3) Install nut caps, if equipped using lug wrench,
do not over tighten.
(4) Remove release liner from removal instructions
label and install label next to jacking instructions
label. Surface must be clean and flat for proper adhe-
sion of label.
EXTERIOR
INSPECTIONÐBODY SEALING
Visually inspect the following seals during the nor-
mal recommended wash. Look for areas where water
may have entered the vehicle.
²Door and window seals
²Windshield
²Backlight
INSPECTION - FIT AND FINISH
(1) Remove all protective coatings/covers.
²Remove protective film from body moldings.
(2) Make sure body is free from paint chips,
scratches, sags, run, dirt or corrosion. Touch up any
minor paint chips and scratches as required.
(3) Ensure that moldings and stripes are aligned
properly.
²Ensure that moldings and stripes are present
and securely fastened to the body.NOTE: Painted-on accent strips require a unique
paint for touch-ups.
(4) Check that the door panels have even gaps and
fit well with adjacent body panels (Fig. 21).
(5) Check that the tailgate has even gaps and fits
well with adjacent panels (Fig. 22).
Fig. 20 WHEEL COVER
Fig. 21 DOOR ALIGNMENT
Fig. 22 TAILGATE ALIGNMENT
30 - 10 NEW VEHICLE PREPARATIONBR/BE
UNDER VEHICLE (Continued)

(6) Check that the hood panel has even gaps and
fits well with adjacent panels (Fig. 23).
(7) Ensure that the body is free from dents and
dings.
INSPECTION - KEYLESS ENTRY
Check operation of keyless entry system and pro-
gram the transmitter/receiver if necessary.
INSPECTION - DOORS AND DOOR LOCKS
(1) Check operation of doors and locks, keyless
entry, security alarm, and tailgate. Adjust strikers
(Fig. 24) and latches (Fig. 25) as required.
(2) Remove any protective covers from the door
sills.
NOTE: Windows should be in the full up position
during these tests (except for the lock tests).
²Open each door (inside and out) to check the
release mechanism and ease of operation.
²Partially close the door to check the open-door
detent.
²Close the door to check the latches and striker.
²Open the door, lower the window depress the
lock plunger and close the door to check the lock.
²Unlock each door (using both keys) to check lock
and key operation.
NOTE: Child proof door locks should be disabled
when delivered to the customer.
Fig. 23 HOOD ALIGNMENT
Fig. 24 DOOR STRIKER
Fig. 25 DOOR LATCH
BR/BENEW VEHICLE PREPARATION 30 - 11
EXTERIOR (Continued)

BODY INTERIOR
INSPECTION - COMPASS
NOTE: Set variance after calibration.
(1) Calibrate and set compass variance (Fig. 26), if
so equipped (use appropriate procedures in service
information).
(2) Remove protective film from overhead console,
if equipped.
INSPECTION - FIT AND FINISH
(1) Remove any interior covers.
(2) Inspect the instrument panel, glove box door
(Fig. 27) and interior moldings for even gaps and
alignments.
(3) Check that the door panel material is clean,
free from wrinkles and installed correctly.
(4) Check that the seat material is clean, secure
and free of wrinkles.
(5) Check that the carpet is clean, secure and free
of wrinkles.
(6) Check that the headliner is clean, free of lint
and dirt smudges.
INSPECTION - LIGHTS AND SWITCHES
(1) Remove protective film from all switch bezels.
(2) Operate and visually inspect all interior lights
and switches, including:
²Dome/map lamps
²Vanity mirror lamps
²Glove box light²Ashtray light
²Cigar lighter light
²All gauge lights
²Radio display
²Door-mounted lights, if equipped
²Illuminated entry system, if equipped
(3) Visually inspect and operate all exterior lights
and their switches, including:
NOTE: Headlamp aim is preset during vehicle
assembly.
²Headlights, including high beam, optical horn
(ªflash to passº) and daylight running lamps (DRL's)
(Fig. 28)
²Tail/stop lamps (including center high-mounted
stop lamp)
²Parking lights Turn signals Brake lights (includ-
ing center high mounted stop lamp)
²Emergency flashers (Fig. 29)
²Fog/driving lights, if equipped
²Off-road or other lights, if equipped
²Cargo bed lights, if equipped
(4) Check ignition switch for proper operation in
all positions (accessory, lock, on, start and off).
INSPECTION - SEAT BELTS, SHOULDER
BELTS, RETRACTORS AND HEAD RESTRAINTS
(1) Inspect all seat belts and harnesses to ensure
that they connect and hold properly.
(2) Inspect the condition of the belts and anchors.
(3) Inspect for proper seat belt retraction.
Fig. 26 COMPASS OPERATION
Fig. 27 GLOVE BOX DOOR
30 - 12 NEW VEHICLE PREPARATIONBR/BE

(4) Check that safety labels regarding the use of
seat belts and air bags are in place (such as on the
sun visors) (Fig. 30).
(5) Ensure head restraints are properly installed.
Inspect the height adjustment for ease of operation.
INSPECTION - SEATS
(1) Remove protective seat, carpet and door covers
(if being delivered) where applicable.
(2) Check that manual/power seat adjustments
work properly for all seats (Fig. 31).²Inspect the operation of front seat mechanical
slides and power adjusters (Fig. 31)
²Check the seatback recliner for ease of release
and operation
²Check the rear seatback latches for ease of
release
²On fold-down rear seats, latch the rear seats
and pull forward on the seats to check that the
latches hold
(3) Check the seat heaters on vehicles equipped
with heated seats.
(4) Check that all seats are securely located in
their adjustable tracks (Fig. 31).
Fig. 31 SEAT CONTROLS
Fig. 28 HEADLAMP SWITCH
Fig. 29 EMERGENCY FLASHER SWITCH
Fig. 30 SEAT BELT LABELS
BR/BENEW VEHICLE PREPARATION 30 - 13
BODY INTERIOR (Continued)

INSPECTION - WINDOWS, DOORS AND LOCKS
(1) Check all power window switches for proper
operation (Fig. 32).
(2) Run all power or manually operated door, quar-
ter and vent windows to the fully closed position to
check operation and sealing.
(3)
(4) Check all power/manual door locks for correct
operation (Fig. 32).
(5)
Ensure that all doors open/close easily (Fig. 33).
(6) Check that the glove box door opens/closes eas-
ily (Fig. 34).
(7) Check that the console door opens/closes easily
(Fig. 35).
INSTALLATION - SHIPPED LOOSE ITEMS
(1) Install the antenna mast.
(2) Install rear license plate holder and front
license plate holder (if required).
(3) Install wheel covers (if required).
Fig. 32 POWER WINDOW AND LOCK SWITCHES
Fig. 33 DOOR OPERATION
Fig. 34 GLOVE BOX DOOR
Fig. 35 CENTER CONSOLE
30 - 14 NEW VEHICLE PREPARATIONBR/BE
BODY INTERIOR (Continued)

ROAD TEST
DESCRIPTION - ROAD TEST INSPECTION
The following items must be inspected during the
road test portion of the new vehicle inspection.
²Check neutral safety switch operation
²Check operation of shift/clutch interlock system
²Check operation of gauges and warning lights
²Check horn operation
²Check operation of turn signals and emergency
flashers
²Check all mirror adjustments, including day/
night function
²Check windshield wipers for proper wipe pattern
and intermittent mode (if equipped)
²Check washer spray pattern
²Check heater, defroster and air conditioning for
proper operation
²Check that the fan operates quietly
²Check the rear window defroster (if equipped)
²Leave air selection lever in the fresh air position
²Check the rear heater and air conditioning for
proper operation
²Check the rear air register locations
²Check that the indicator lamps operate properly
²Check the operation of the radio, cassette and/or
compact disc player, and that sound quality is good
²Ensure that the clock displays the correct time
²Check that the trip computer/maintenance
reminder operates in all modes
²Check all speed control functions
²Check the service brakes to ensure that they
stop the vehicle in a straight line, without noise,
shudder or vibration
²Check the brake warning light
²Check the parking brake operation
²Check the engine's performance
²Check the transmission's performance for
smooth, quiet operation. If the vehicle is a 4x4, check
that the transfer case shifts easily among all ranges
²Check Autostick function (if equipped)
²Check the vehicle's steering and handling
²The steering wheel should be centered when
traveling in a straight line
²The vehicle should not pull or vibrate
²Check for squeaks, rattles and wind noise
²Check any other vehicle aspects you believe are
important, but that may not be included on the New
Vehicle Preparation Form
²Fill fuel tank with specified grade of fuel
INSPECTION - FUEL
Fill fuel tank with specified grade of gasoline (reg-
ular, midgrade or premium).
INSPECTION - OTHER
As part of DaimlerChrysler's Customer One philos-
ophy, the ªOtherº blank is provided on the New Vehi-
cle Preparation Form. This is designed to encourage
you to check any aspects of vehicle operation that
you believe are important to your customers, but that
do not appear elsewhere on the form.
INSPECTION - SQUEAKS, RATTLES AND WIND
NOISE
(1) Make sure that the instrument panel, glove
box, seats, steering wheel and column are free from
squeaks and rattles. Tighten any obvious loose fas-
teners.
(2) Check that the windows and doors are free
from squeaks, rattles and wind noise.
(3) Check that the vehicle exterior is free from
squeaks, rattles and noise, front and rear.
(4) Make sure that all interior panels are free from
squeaks and rattles.
INSPECTION - STEERING AND HANDLING
(1) Check that the power assist works properly (if
equipped). Steering should not require excessive
effort.
(2) Make sure the steering wheel does not vibrate
at idle or road speed.
(3) Ensure that the steering wheel is centered
when traveling straight ahead.
(4) Check that the vehicle does not drift to one
side.
(5) Make sure that the vehicle does not vibrate/
shake.
INSPECTION - TRANSMISSION/TRANSFER
CASE
AUTOMATIC TRANSMISSION
(1) Make sure that the park lock holds the vehicle
With the vehicle on a grade, put automatic trans-
mission in PARK and slowly release the service
brake to see if park lock holds. If it does not hold, the
transmission requires further service.
(2) Make sure shift lever operates easily/ smoothly
(Fig. 36).
Check for smooth shifting. Check for proper
upshifting and downshifting.
MANUAL TRANSMISSION
(1) Check that the shifter operates easily (Fig. 38).
(2) Make sure that the clutch operates smoothly
(Fig. 37).
(3) Look for proper synchronization.
The gears should not grind.
BR/BENEW VEHICLE PREPARATION 30 - 15