cooling DODGE RAM 2500 DIESEL 2004 3.G User Guide

NBody Lubrication.....................340
NWindshield Wiper Blades................341
NWindshield Washers...................341
NExhaust System......................342
NCooling System.......................343
NFan ...............................347
NCharge Air Cooler (Inter-Cooler)..........347
NHoses And Vacuum/Vapor Harnesses.......348
NBrake System........................348
NClutch Linkage.......................350
NClutch Hydraulic System................351
NPropeller Shaft Universal Joints...........351NRear Axle And 4X4 Front Driving Axle Fluid
Level..............................351
NTransfer Case Ð If Equipped.............352
NManual Transmission Ð If Equipped.......352
NAutomatic Transmission................353
NFront Wheel Bearings..................355
NSelection Of Lubricating Grease...........356
NNoise Control System Required
Maintenance & Warranty................357
NAppearance Care And Protection From
Corrosion...........................362
mFuse And Relay Center...................366
mVehicle Storage........................366
318 MAINTAINING YOUR VEHICLE

²Do 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.
²If 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.
²To avoid burns, remember that the engine components
will stay hot after the engine is shut off.
²Do not use gasoline or other flammable materials to
clean parts. Always use approved cleaning solvents.
²Relieve 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 utilizespressure. Do not check for pressure leaks with your
hand. High pressure oil or fuel can cause personal
injury.
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.
²Important:All maintenance other than that listed in
this manual, as well as some procedures listed here,
MUSTbe performed by your local Dodge Truck
Dealer. Your authorized Dodge Dealer has been
trained and has the necessary parts to maintain your
engine.
324 MAINTAINING YOUR VEHICLE

Always check the condition of the used oil. This can give
you an indication of some engine problems that might
exist.
²Thin, black oil indicates fuel dilution.
²Milky discoloration indicates coolant dilution.
Clean the area around the oil filter base. Remove the filter
from the underside of the vehicle using a cap style oil
filter wrench.
Clean the gasket surface of the filter mount. The filter
gasket can stick on the filter mount. Make sure it is
removed.
Change the engine oil filter with every engine oil change.
Only a high quality MOPAR filter should be used to
assure most efficient service.
CAUTION!
The filtering medium of other aftermarket filters
may disintegrate. Debris from failed filters may plug
the piston oil cooling nozzles, resulting in scuffed
pistons and engine failure.
CAUTION!
Fill the oil filter element with clean oil before
installation. Use the same type oil that will be used
in the engine. When filling the oil filter, prevent
foreign material from falling into the filter. Severe
engine damage may occur.
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Cooling System
Cooling System Maintenance
At the intervals shown in the Maintenance Schedules
Section of the manual, the system should be drained,
flushed and filled.
Inspection
Coolant protection checks should be made every 12
months (prior to the onset of freezing weather, where
applicable). If coolant is dirty or rusty in appearance, the
system should be drained, flushed and refilled with fresh
coolant as specified.
Inspect the entire cooling system for leaks. Check the face
of the radiator for any accumulation of bugs, leaves, or
other foreign matter. If dirty, clean the radiator core with
a garden hose. With the engine OFF, gently spray water
from the back of the radiator core. Check coolant bottle
tube for condition and tightness of connections at coolant
bottle and radiator.Check the coolant pressure cap and coolant bottle for
proper vacuum sealing. With the engine at normal oper-
ating temperature, note the level of the coolant in the
coolant bottle. Without removing the pressure cap (with
the engine off), drain a small amount of coolant from the
radiator drain cock. If the coolant level in the coolant
bottle drops, the system is sealing properly.
Extremely cold ambient temperature may require the
addition of a ªwinter frontº for effective operation of the
cab heating/cooling system. Make certain that a percent-
age of the radiator is exposed for adequate air flow
through the charge air cooler and automatic transmission
oil cooler. The percentage of opening must be increased
with the increasing ambient air temperature and/or
engine load. If the cooling fan can be heard cycling
frequently, increase the size of the opening in the winter
front.
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Coolant bottle level check
The coolant reserve system provides a quick visual
method of determining that the coolant level is adequate.
With the engine idling, and warmed to the normal
operating temperature, the level of the coolant on the
coolant bottle should be between the fluid level marks.
Check the coolant level whenever the hood is raised.
The radiator normally remains completely full, so there is
no longer a need to remove the coolant pressure cap
except for checking coolant freeze point or replacement
with new antifreeze coolant.
WARNING!
Never add coolant to the radiator when the engine is
overheated. Do not loosen or remove pressure cap to
cool overheated engine! The coolant is under pres-
sure and severe scalding could result.
Drain, Flush And Refill
At intervals shown on the Maintenance Schedules, the
system should be drained, flushed and refilled. Refer to
your dealer or consult a service manual for proper
procedures.
Adding Coolant
When adding coolant or refilling system, a 50% solution
of ethylene glycol antifreeze coolant in water should be
used. Higher concentrations (not to exceed 65%) are
required if temperatures below -34 ÉF (-37 ÉC) are antici-
pated. Use only high purity water such as distilled or
deionized water when mixing the water/antifreeze solu-
tion. 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
maintain the proper level of protection against freezing
according to the temperatures occurring in the area
where the vehicle is operated.
344 MAINTAINING YOUR VEHICLE

NOTE:Mixing coolant types will decrease the life of the
engine coolant and will require more frequent coolant
changes.
When additional coolant is needed to maintain the
proper level, add the recommended concentration of
antifreeze and water to the overflow bottle. Do not
overfill.
NOTE:Failure to follow the antifreeze concentration
and replacement recommendations, or failure to use
antifreeze formulated to prevent corrosion of all cooling
system metals, may result in radiator plugging, overheat-
ing, or cooling system leaks such as in core hole plugs.WARNING!
Never add coolant to the radiator when the engine is
overheated. Do not loosen or remove pressure cap to
cool an overheated engine. The coolant is under
pressure and severe scalding could result.
Recommended Engine Coolant
Refer to Recommended Fluids, Lubricants and Genuine
Parts for the correct Fluid type.
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CAUTION!
Mixing of coolants other than specified (HOAT),
may result in engine damage that may not be cov-
ered under the new vehicle warranty, and decreased
corrosion protection. If a non-HOAT coolant is intro-
duced into the cooling system in an emergency, it
should be replaced with the specified coolant as
soon as possible.
Do not use plain water alone or alcohol base anti-
freeze products. Do not use additional rust inhibi-
tors or antirust products, as they may not be compat-
ible with the radiator coolant and may plug the
radiator.
This vehicle has not been designed for use with
Propylene Glycol based coolants. Use of Propylene
Glycol based coolants is not recommended.
Disposal Of Used Engine Coolant
Used ethylene glycol based engine coolant is a regulated
substance requiring proper disposal. Check with your
local authorities to determine the disposal rules for your
community. Do not store ethylene glycol-based engine
coolant in open containers or allow it to remain in
puddles on the ground. Prevent ingestion by animals and
children. If ingested by a child, contact a physician
immediately. Clean up any ground spills immediately.
Coolant Pressure Cap
The coolant pressure cap must be fully tightened to
prevent loss of coolant and to insure that coolant will
return to the radiator from the coolant reserve tank.
346 MAINTAINING YOUR VEHICLE

WARNING!
Never add coolant when the engine is overheated.
Do not loosen or remove the pressure cap to cool an
overheated engine. Heat causes pressure 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.
CAUTION!
Recheck the cooling system to insure total system is
full of coolant.
Fan
Inspection
Check the fan for cracks and bent or broken blades. If any
of these conditions exist, you must replace the fan. Make
sure it is securely mounted.
NOTE:This service procedure must be performed by a
trained service technician. Make arrangements with your
authorized Dodge Truck Dealer for this inspection.
Charge Air Cooler (Inter-Cooler)
The charge air cooler is positioned between the radiator
and the air conditioner condenser. Air enters the engine
through the air cleaner and passes through the turbo-
charger where it is pressurized. This pressurized air
rapidly reaches high temperature. The air is then directed
through a hose to the charge air cooler and through
another hose to the intake manifold of the engine. The air
entering the engine has been cooled by about 50 to 100
MAINTAINING YOUR VEHICLE 347
7

degrees Fahrenheit. This cooling process enables more
efficient burning of fuel resulting in fewer emissions.
To guarantee optimum performance of the system, keep
the surfaces of the charge air cooler, condenser and
radiator clean and free of debris. Periodically check the
hoses leading to and from the charge air cooler for cracks
or loose clamps resulting in loss of pressure and reduced
engine performance.
Hoses And Vacuum/Vapor Harnesses
Inspect surfaces of hoses and nylon tubing for evidence
of heat and mechanical damage. Hard or soft spots,
brittle rubber, cracking, tears, cuts, abrasions, and exces-
sive swelling indicate deterioration of the rubber.
Pay particular attention to those hoses nearest to high
heat sources such as the exhaust manifold. Inspect hose
routing to be sure hoses do not come in contact with any
heat source or moving component which may cause heat
damage or mechanical wear.Insure nylon tubing in these areas has not melted or
collapsed.
Inspect all hose connections such as clamps and cou-
plings to make sure they are secure and no leaks are
present.
Components should be replaced immediately if there is
any evidence of wear or damage that could cause failure.
Brake System
Power Disc Brakes (Front and Rear)
Disc brakes do not require adjustment; however, several
hard stops during the break-in period are recommended
to seat the linings and wear off any foreign material.
Brake Master Cylinder
The 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.
348 MAINTAINING YOUR VEHICLE

²AIR CLEANER
þRemoval of the air cleaner.
þRemoval of the air cleaner filter element from the air
cleaner housing.
þRemoval of the air ducting.
²EXHAUST SYSTEM
þRemoval or rendering inoperative exhaust system
components including the muffler or tailpipe.
²ENGINE COOLING SYSTEM
þRemoval or rendering inoperative the fan clutch.
þRemoval 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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