maintenance procedures Ram 1500 2016 Diesel Supplement

A MESSAGE FROM FCA US LLC
FCA US LLC welcomes you as a turbocharged diesel-
powered truck owner. Your diesel truck will sound, feel,
drive, and operate differently from a gasoline-powered
truck. It is important that you read and understand this
manual.
Almost 100% of the heavy trucks in the United States and
Canada are diesel-powered because of the fuel economy,
rugged durability, and high torque which permits pulling
heavy loads.
You may find that some of the starting, operating, and
maintenance procedures are different. However, they are
simple to follow and careful adherence to them will
ensure that you take full advantage of the features of this
engine.NOTE:
•
Some aftermarket products may cause severe engine/
transmission and/or exhaust system damage. Your
vehicle’s Powertrain Control Systems can detect and
store information about vehicle modifications that
increase horsepower and torque output such as
whether or not performance-enhancing powertrain
components, commonly referred to as downloaders,
power boxes, or performance chips have been used.
• Any chassis/suspension or tire size modifications to
the vehicle will effect the performance of the Adaptive
Cruise Control and Forward Collision Warning Sys-
tem.
This information cannot be erased and will stay in the
system’s memory even if the modification is removed.
This information can be retrieved by FCA US LLC, and
service and repair facilities, when servicing your vehicle.
8 INTRODUCTION

Water in Fuel Indicator Light — If Equipped
Yellow TelltaleLight What It Means
Water in Fuel Indicator Light
The “Water In Fuel Indicator Light” will illuminate when there is water detected in the fuel
filters. If this light remains on, DO NOT start the vehicle before you drain the water from
the fuel filters to prevent engine damage. Refer to “Maintenance Procedures” in “Maintain-
ing Your Vehicle” for further information.
Low Diesel Exhaust Fluid (DEF) Indicator Light — If Equipped
Yellow Telltale
Light What It Means
Low Diesel Exhaust Fluid (DEF) Indicator Light
The Low Diesel Exhaust Fluid (DEF) Indicator will illuminate if the vehicle is low on Diesel
Exhaust Fluid (DEF). Refer to “Starting And Operating” for further information.
24 UNDERSTANDING YOUR INSTRUMENT PANEL

Diesel Indicator Lights
This area will show reconfigurable amber telltales that
relate to your diesel. These telltales include:
NOTE:“Refer to your OM on DVD for additional telltale
information”
Water In Fuel Indicator Light
The “Water In Fuel Indicator Light” will illumi-
nate when there is water detected in the fuel
filters. If this light remains on, DO NOT start the
vehicle before you drain the water from the fuel
filters to prevent engine damage. Refer to “Maintenance
Procedures/Draining Fuel/Water Separator Filters” in
“Maintaining Your Vehicle” for further information.
Wait To Start Light
The “Wait To Start” telltale will illuminate for
approximately two seconds when the ignition is
turned to the RUN position. It’s duration may be longer based on colder operating conditions. Vehicle will not
initiate start until telltale is out. Refer to “Starting Proce-
dures” in “Starting And Operating” for further informa-
tion.
NOTE:
The “Wait To Start” telltale may not illuminate if
the intake manifold temperature is warm enough.
Low Diesel Exhaust Fluid Light
This telltale will turn on to indicate the Diesel
Exhaust Fluid (DEF) is low.
Diesel Particulate Filter (DPF) Messages
The diesel engine meets all EPA Heavy Duty Diesel
Engine Emissions Standards, resulting in one of the
lowest emitting diesel engines ever produced. To achieve
these emissions standards, your vehicle is equipped with
a state-of-the-art engine and exhaust system. These sys-
tems are seamlessly integrated into your vehicle and
48 UNDERSTANDING YOUR INSTRUMENT PANEL

NOTE:Engine start up in very low ambient temperature
could result in evident white smoke. This condition will
disappear as the engine warms up.
CAUTION!
• The engine is allowed to crank as long as 30
seconds. If the engine fails to start during this
period, please wait at least two minutes for the
starter to cool before repeating start procedure.
• If the “Water in Fuel Indicator Light” remains on,
DO NOT START engine before you drain the water
from the fuel filters to avoid engine damage. Refer
to “Maintenance Procedures/Draining Fuel/Water
Separator Filter” in “Maintaining Your Vehicle” for
further information.
Normal Starting
Normal starting of either a warm or cold engine is
obtained without pumping or pressing the accelerator
pedal. Turn the key fob to the START position and release
when the engine starts. If the engine fails to start, turn the
key fob to the OFF position, wait five seconds, then
repeat the “Normal Starting” procedure.
Automatic Transmission
Start the engine with the transmission gear selector in the
PARK position. Apply the brake before shifting to any
driving range.
Tip Start Feature
Do not press the accelerator. Cycle the ignition switch
briefly to the START position and release it. The starter
motor will continue to run but will automatically disen-
gage when the engine is running.
64 STARTING AND OPERATING

Keyless Enter-N-Go
This feature allows the driver to oper-
ate the ignition switch with the push
of a button, as long as the Remote
Start/Keyless Enter-N-Go Key Fob is
in the passenger compartment.
Normal Starting Procedure — Keyless Enter-N-Go
Observe the instrument panel cluster lights when starting
the engine.
NOTE:Normal starting of either a cold or a warm
engine is obtained without pumping or pressing the
accelerator pedal
1. Always apply the parking brake. 2. Press and hold the brake pedal while pushing the
ENGINE START/STOP button once.
NOTE: A delay of the start of up to five seconds is
possible under very cold conditions. The Wait to Start
telltale will be illuminated during the pre-heat process,
When the engine Wait To Start light goes off the engine
will automatically crank.
CAUTION!
If the “Water in Fuel Indicator Light” remains on, DO
NOT START the engine before you drain the water
from the fuel filters to avoid engine damage. Refer to
“Maintenance Procedures/Draining Fuel/Water Sepa-
rator Filter” in “Maintaining Your Vehicle” for fur-
ther information.
4
STARTING AND OPERATING 65

NOTE:
•Use of Climatized Ultra Low Sulfur Diesel Fuel or
Number 1 Ultra Low Sulfur Diesel Fuel results in a
noticeable decrease in fuel economy.
• Climatized Ultra Low Sulfur Diesel Fuel is a blend of
Number 2 Ultra Low Sulfur and Number 1 Ultra Low
Sulfur Diesel Fuels which reduces the temperature at
which wax crystals form in fuel.
• The fuel grade should be clearly marked on the pump
at the fuel station.
• The engine requires the use of “Ultra Low Sulfur
Diesel Fuel”. Use of incorrect fuel could result in
engine and exhaust system damage. Refer to “Fuel
Requirements” in “Starting And Operating” for fur-
ther information.
• Commercially available fuel additives are not neces-
sary for the proper operation of your diesel engine. However, if seasonably adjusted fuel is not available
and you are operating below 20°F (-6°C), MOPAR
Premium Diesel Fuel Treatment (or equivalent) may be
beneficial to avoid fuel gelling.
Engine Oil Usage
Refer to “Maintenance Procedures” in “Maintaining Your
Vehicle” for the correct engine oil viscosity.
Winter Front Usage
A winter front or cold weather cover is to be used in
ambient temperatures below 32°F (0°C), especially dur-
ing extended idle conditions to reduce condensation
build-up within engine crankcase. If a winter front or
cold weather cover is to be used, a percentage of the total
grille opening area must be left uncovered to provide
sufficient air flow to 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
4
STARTING AND OPERATING 69

provide good performance. If the vehicle is exposed to
extreme cold (below 20°F or -7°C), or is required to
operate at colder-than-normal conditions for prolonged
periods, use climatized No. 2 diesel fuel or dilute the No.
2 diesel fuel with 50% No. 1 diesel fuel. This will provide
better protection from fuel gelling or wax-plugging of the
fuel filters.
WARNING!
Do not use alcohol or gasoline as a fuel blending
agent. They can be unstable under certain conditions
and hazardous or explosive when mixed with diesel
fuel.
Diesel fuel is seldom completely free of water. To prevent
fuel system trouble, drain the accumulated water from
the fuel/water separator using the fuel/water separator
drain provided on the fuel filter housing. If you buy good
quality fuel and follow the cold weather advice above, fuel conditioners should not be required in your vehicle.
If available in your area, a high cetane “premium” diesel
fuel may offer improved cold-starting and warm-up
performance.
CAUTION!
If the “Water in Fuel Indicator Light” remains on, DO
NOT START engine before you drain the water from
the fuel filter(s) to avoid engine damage. Refer to
“Maintenance Procedures/Draining Fuel/Water Sepa-
rator Filter” in “Maintaining Your Vehicle” for fur-
ther information.
Fuel Specifications
This diesel engine has been developed to take advantage
of the high energy content and generally lower cost
No. 2 Ultra Low Sulfur diesel fuel or No. 2 Ultra Low
Sulfur climatized diesel fuels.
74 STARTING AND OPERATING

Avoid Using Contaminated Fuel
Fuel that is contaminated by water or dirt can cause
severe damage to the engine fuel system. Proper main-
tenance of the engine fuel filter and fuel tank is essential.
Refer to “Maintenance Procedures” in “Maintaining Your
Vehicle” for further information.
Bulk Fuel Storage — Diesel Fuel
If you store quantities of fuel, good maintenance of the
stored fuel is also essential. Fuel contaminated with
water will promote the growth of “microbes.” These
microbes form “slime” that will clog the fuel filtration
system and lines. Drain condensation from the supply
tank and change the line filter on a regular basis.
NOTE:When a diesel engine is allowed to run out of
fuel, air is pulled into the fuel system. If the vehicle will not start, refer to “Maintenance
Procedures/Priming If The Engine Has Run Out Of Fuel”
in “Maintaining Your Vehicle” for further information.
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.
Diesel Exhaust Fluid Storage
Diesel Exhaust Fluid (DEF) is considered a very stable
product with a long shelf life. If DEF is kept in tempera-
tures between 10° and 90°F (-12° and 32°C), it will last a
minimum of one year.
4
STARTING AND OPERATING 83

MAINTAINING YOUR VEHICLE
CONTENTS
ENGINE COMPARTMENT — 3.0L DIESEL .....90
 MAINTENANCE PROCEDURES ............91
▫ Engine Oil ...........................92
▫ Engine Air Cleaner Filter ................94
▫ Draining Fuel/Water Separator Filter ........97
▫ Underbody Mounted Fuel Filter Replacement. .100
▫ Priming If The Engine Has Run Out Of Fuel . .101
▫ Intervention Regeneration Strategy — Message
Process Flow ....................... .103▫
Maintenance-Free Batteries ..............103
▫ Cooling System ..................... .104
▫ Charge Air Cooler — Inter-Cooler .........110
▫ Brake System ........................110
 FLUID CAPACITIES ....................113

FLUIDS, LUBRICANTS AND GENUINE PARTS . . .114
▫ Engine .............................114
▫ Chassis ............................118
5

MAINTENANCE PROCEDURES
The pages that follow contain therequiredmaintenance
services determined by the engineers who designed your
vehicle.
Besides those maintenance items specified in the fixed
maintenance schedule, there are other components which
may require servicing or replacement in the future.
CAUTION!
• Failure to properly maintain your vehicle or per-
form repairs and service when necessary could
result in more costly repairs, damage to other
components or negatively impact vehicle perfor-
mance. Immediately have potential malfunctions
examined by an authorized dealership or qualified
repair center.
(Continued)
CAUTION! (Continued)
•Your vehicle has been built with improved fluids
that protect the performance and durability of your
vehicle and also allow extended maintenance inter-
vals. Do not use chemical flushes in these compo-
nents as the chemicals can damage your engine,
transmission, power steering or air conditioning.
Such damage is not covered by the New Vehicle
Limited Warranty. If a flush is needed because of
component malfunction, use only the specified
fluid for the flushing procedure.
5
MAINTAINING YOUR VEHICLE 91