fuel DODGE RAM 2500 DIESEL 2004 3.G Service Manual

WARNING!
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.
NOTE:Due to lack of lubricants in alcohol or gasoline,
the use of these fuels can cause damage to the fuel
system. Hence, use of these fuels will void the warranty
on the engine.
NOTE:As sufficient testing as not been completed,
organically blended diesel fuels (e.g. biodiesel, ethanol,
and methanol blends) are not recommended or approved
for use with your Cummins Diesel equipped Dodge Ram
Truck.NOTE:In addition, commercially available fuel addi-
tives are not necessary for the proper operation of your
Cummins Diesel equipped Dodge Ram Truck.
Maintenance Free Batteries
The top of the maintenance free batteries are perma-
nently sealed. You will never have to add water, nor is
periodic maintenance required.
336 MAINTAINING YOUR VEHICLE

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

2. Pull bulb straight from the connector.
3. Reverse procedure for installation of bulbs and hous-
ing.FLUID CAPACITIES
FLUID CAPACITIES U.S. Metric
Fuel
2500 Shortbed Models 34 gal. 128L
2500 Longbed Models 35 gal. 132L
3500 Shortbed Models 34 gal. 128L
3500 Longbed Models 35 gal. 132L
Engine Oil
5.9L Diesel Engine I-6 12.0 qts. 11.4L
Cooling System
5.9L Diesel Engine I-6 7 gal. 26.5L
MAINTAINING YOUR VEHICLE 379
7

RECOMMENDED FLUIDS, LUBRICANTS AND GENUINE PARTS
Engine
Component Fluids, Lubricants and Genuine Parts
Engine Coolant MopartAntifreeze/Coolant 5 Year/100,000 Mile Formula HOAT (Hybrid Or-
ganic Additive Technology) P/N 5011764AB or equivalent.
Engine Oil For the proper quality and SAE Grade oil for your engine, refer to the sec-
tion9Maintenance Procedures.9
Engine Oil Filter MopartEngine Oil Filter, P/N 05083285AA or equivalent.
Engine Fuel Filter MopartFuel Filter, P/N 05015581AB or equivalent.
Fuel Selection Refer to the section9Fuel Requirements9for detailed information on fuel se-
lection.
380 MAINTAINING YOUR VEHICLE

²Off-road or desert operation.
²Extensive operation at high engine speeds (greater
than 2900 rpm) and loads (greater than 70% throttle).
NOTE:Most vehicles are operated under the conditions
listed for Schedule9B9.
Second is ScheduleªAº. It is for vehicles that are not
operated under any of the conditions listed under Sched-
ule9B9.
Use the schedule that best describes your driving condi-
tions. Where time and mileage are listed, follow the
interval that occurs first.
CAUTION!
Failure to perform the required maintenance 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.
Once a Month
²Check tire pressure and look for unusual wear or
damage.
²Inspect the batteries and clean and tighten the termi-
nals as required.
MAINTENANCE SCHEDULES 385
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Miles 3,750 7,500 11,250 15,000 18,750
(Kilometers) (6 000) (12 000) (18 000) (24 000) (30 000)
Change engine oil and engine oil filter. X X
Rotate tires. X X
Lubricate outer tie rod ends 2500/3500 (4X4) mod-
els only.XX
Inspect water pump weep hole for blockage. X
Replace fuel filter element. Clean the water in fuel
sensor.X
Change rear axle fluid.X
Change front axle fluid (4X4). X
Inspect brake linings.X
Inspect and adjust parking brake if necessary. X
388 SCHEDULE ªBº
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Miles 22,500 26,250 30,000 33,750 37,500
(Kilometers) (36 000) (42 000) (48 000) (54 000) (60 000)
Change engine oil and engine oil filter. X X X
Rotate tires. X X X
Lubricate outer tie rod ends 2500/3500 (4X4) mod-
els only.XXX
Inspect drive belt, replace as required. X
Inspect fan hub. X
Inspect damper. X
Inspect water pump weep hole for blockage. X
Replace fuel filter element. Clean the water in fuel
sensor.X
Change rear axle fluid. X
Change front axle fluid (4X4). X
Check transfer case fluid level (4X4). X
Drain and refill automatic transmission fluid. Re-
place filter and adjust bands.X
SCHEDULE ªBº 389
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Miles 41,250 45,000 48,750 52,500 56,250
(Kilometers) (66 000) (72 000) (78 000) (84 000) (90 000)
Change engine oil and engine oil filter. X X
Rotate tires. X X
Lubricate outer tie rod ends 2500/3500 (4X4) mod-
els only.XX
Inspect drive belt, replace as required. X
Inspect water pump weep hole for blockage. X
Replace fuel filter element. Clean the water in fuel
sensor.X
Inspect brake linings. X
Inspect and adjust parking brake if necessary. X
Change rear axle fluid. X
Change front axle fluid (4X4). X
390 SCHEDULE ªBº
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Miles 60,000 63,750 67,500 71,250 75,000
(Kilometers) (96 000) (102 000) (108 000) (114 000) (120 000)
Change engine oil and engine oil filter. X X X
Rotate tires. X X X
Lubricate outer tie rod ends 2500/3500 (4X4) models only. X X X
Inspect drive belt, replace as required. X
Inspect fan hub. X
Inspect damper. X
Inspect water pump weep hole for blockage. X X
Replace fuel filter element. Clean the water in fuel sensor. X X
Inspect front wheel bearings. X
Change rear axle fluid. X X
Change front axle fluid (4X4). X X
Inspect brake linings. X X
Inspect and adjust parking brake if necessary. X X
Drain and refill transfer case fluid (4X4). X
Drain and refill automatic transmission fluid. Replace fil-
ter and adjust bands.X
SCHEDULE ªBº 391
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Miles 78,750 82,500 86,250 90,000 93,750
(Kilometers) (126 000) (132 000) (138 000) (144 000) (150 000)
Change engine oil and engine oil filter. X X
Rotate tires. X X
Lubricate outer tie rod ends 2500/3500 (4X4) models only. X X
Inspect drive belt, replace as required. X
Change rear axle fluid.X
Change front axle fluid (4X4). X
Check transfer case fluid level (4X4). X
Inspect fan hub.X
Inspect damper.X
Inspect water pump weep hole for blockage. X
Replace fuel filter element. Clean the water in fuel sensor. X
Inspect front wheel bearings. X
Inspect brake linings.X
Inspect and adjust parking brake if necessary. X
Drain and refill automatic transmission fluid. Replace fil-
ter and adjust bands.X
392 SCHEDULE ªBº
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