Dodge Diesel (2004 year). Manual

edges of the instrument panel. The demisters also pro-
vide extra air ducts for circulation. They are in operation
whenever the Floor, Mix or Defrost modes are in use.

NOTE:

When you turn off the engine you may hear a

hissing sound from under the hood for a short period of
time. This is a normal condition that occurs if the air
conditioning system has been on. It is not an indication of
a problem with the air conditioning system.

Operating Tips

Fast Cooldown
For a fast cooldown, turn the blower fan rotary knob to
the extreme right position, turn the mode control to the
panel fresh position, press the snowflake button to turn
on the air conditioning, and drive with the windows
open for the first few minutes. Once the hot air has been
expelled, close the windows and press the Recirculation
pushbutton. When a comfortable condition has been

reached, choose a mode position and adjust the tempera-
ture control slide and blower speed as necessary to
maintain comfort. For high humidity conditions it may
be necessary to remain in the Recirculation mode to
maintain comfort.

Window Fogging
Windows will fog on the inside when the humidity inside
the vehicle is high. This often occurs in mild or cool
temperatures when it’s rainy or humid. In most cases
turning on the Air-conditioning (pressing the snowflake
button) will clear the fog. Adjust the temperature control,
air direction and blower speed to maintain comfort.

As the temperature gets colder it may be necessary to
direct air onto the windshield by using MIX Mode
position on the control. Adjust the temperature control
and blower speed to maintain comfort. Higher blower

196

UNDERSTANDING YOUR INSTRUMENT PANEL

speeds will reduce fogging. Interior fogging on the
windshield can be quickly removed by selecting the
defrost mode.

Regular cleaning of the inside of the windows with a
non-filming cleaning solution (vinegar and water works
very well) will help prevent contaminates (cigarette
smoke, perfumes, etc.) from sticking to the windows.
Contaminates increase the rate of window fogging.

Summer Operation
Air conditioned vehicles must be protected with a high
quality antifreeze coolant during summer to provide
proper corrosion protection and to raise the boiling point
of the coolant for protection against overheating. A 50 %
concentration is recommended. Refer to Recommended
Fluids and Genuine Parts for the proper coolant type.

When using the air conditioner in extremely heavy traffic
in hot weather especially when towing a trailer, addi-
tional engine cooling may be required. If this situation is

encountered, operate the transmission in a lower gear to
increase engine RPM, coolant flow and fan speed. When
stopped in heavy traffic, it may be necessary to shift into
NEUTRAL and depress the accelerator slightly for fast
idle operation to increase coolant flow and fan speed.

NOTE:

On models equipped with Diesel engines, the

idle speed will automatically increase to 1000 rpm at
elevated coolant temperatures to improve engine cooling.

Your air conditioning system is also equipped with an
automatic recirculation system. When the system senses
a heavy load or high heat conditions, it may use partial
Recirculation A/C mode to provide additional comfort.

Winter Operation
When operating the system during the winter months,
make sure the air intake, located directly in front of the
windshield, is free of ice, slush, snow, or other obstruc-
tions.

UNDERSTANDING YOUR INSTRUMENT PANEL

197

STARTING AND OPERATING

CONTENTS

m Ignition/Starter Switch . . . . . . . . . . . . . . . . . . . 204

▫ Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
▫ Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
▫ On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
▫ Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
▫ ACC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
▫ Manual Transmission Key Release Button . . . . 205
▫ Key Reminder . . . . . . . . . . . . . . . . . . . . . . . 205

m Starting Procedures . . . . . . . . . . . . . . . . . . . . . 205

▫ Normal Starting Procedure — Engine

Manifold Airtemperature Above 66°F (19°C) . . 206

▫ Starting Procedure — Engine Manifold Air

Temperature Below 66°F (19°C) . . . . . . . . . . . 207

▫ Starting Fluids . . . . . . . . . . . . . . . . . . . . . . . 210

m Normal Operation . . . . . . . . . . . . . . . . . . . . . . 211

▫ Cold Weather Precautions . . . . . . . . . . . . . . . 211
▫ Engine Idling — In Cold Weather . . . . . . . . . . 214
▫ Stopping The Engine . . . . . . . . . . . . . . . . . . . 215
▫ Engine Speed Control . . . . . . . . . . . . . . . . . . 216

▫ Operating Precautions . . . . . . . . . . . . . . . . . . 216
▫ Cooling System Tips — Automatic

Transmission . . . . . . . . . . . . . . . . . . . . . . . . 216

m Transmission Shifting . . . . . . . . . . . . . . . . . . . . 218

▫ Four-Speed Overdrive Automatic

Transmission — If Equipped . . . . . . . . . . . . . 218

▫ Manual Transmission – 5–Speed

(NV- 4500) — If Equipped . . . . . . . . . . . . . . . 222

▫ Manual Transmission — 6-Speed

(NV-5600) — If Equipped . . . . . . . . . . . . . . . 224

m Four-Wheel- Drive Operation — If Equipped . . . 226

▫ Manually Shifted Transfer Case Operating

Information/Precautions . . . . . . . . . . . . . . . . 226

▫ Shifting Procedure - Manually Shifted Transfer

Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

▫ Transfer Case Reminder Light . . . . . . . . . . . . 230
▫ Electronically Shifted Transfer Case

Operating Information/Precautions . . . . . . . . 230

▫ Shifting Procedure - Electronically Shifted

Transfer Case . . . . . . . . . . . . . . . . . . . . . . . . 234

m Limited-Slip Differential — If Equipped . . . . . . . 237
m Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . 238
m Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . 239

▫ Brake Noise . . . . . . . . . . . . . . . . . . . . . . . . . 240
▫ Four-Wheel Anti-Lock Brake System . . . . . . . . 240

m Power Steering . . . . . . . . . . . . . . . . . . . . . . . . 242
m Tire Safety Information . . . . . . . . . . . . . . . . . . . 243

▫ Tire Markings . . . . . . . . . . . . . . . . . . . . . . . . 243
▫ Tire Identification Number (TIN) . . . . . . . . . . 246

200

STARTING AND OPERATING

▫ Tire Loading And Tire Pressure . . . . . . . . . . . 247

m Tires—General Information . . . . . . . . . . . . . . . . 251

▫ Tire Pressure . . . . . . . . . . . . . . . . . . . . . . . . . 251
▫ Tire Inflation Pressures . . . . . . . . . . . . . . . . . 252
▫ Radial-Ply Tires . . . . . . . . . . . . . . . . . . . . . . 255
▫ Compact Spare Tire — If Equipped . . . . . . . . . 255
▫ Tire Spinning . . . . . . . . . . . . . . . . . . . . . . . . 256
▫ Tread Wear Indicators . . . . . . . . . . . . . . . . . . 257
▫ Replacement Tires . . . . . . . . . . . . . . . . . . . . . 257
▫ Alignment And Balance . . . . . . . . . . . . . . . . . 258

m Supplemental Tire Pressure Information . . . . . . . 259
m Tire Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
m Snow Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . 261

m Tire Rotation Recommendations . . . . . . . . . . . . 261

▫ Dual Rear Wheels . . . . . . . . . . . . . . . . . . . . . 263

m Engine Runaway . . . . . . . . . . . . . . . . . . . . . . . 264
m Fuel Requirements . . . . . . . . . . . . . . . . . . . . . . 264

▫ Adding Fuel . . . . . . . . . . . . . . . . . . . . . . . . . 265
▫ Bulk Fuel Storage . . . . . . . . . . . . . . . . . . . . . 267
▫ Fuel Specifications . . . . . . . . . . . . . . . . . . . . 267

m Vehicle Loading . . . . . . . . . . . . . . . . . . . . . . . . 269

▫ Certification Label . . . . . . . . . . . . . . . . . . . . . 269

m Trailer Towing . . . . . . . . . . . . . . . . . . . . . . . . . 272

▫ To Maintain Warranty Coverage . . . . . . . . . . . 272
▫ Axle Lubricant And Trailer Towing . . . . . . . . . 274
▫ Trailer Towing Recommendations . . . . . . . . . . 274

STARTING AND OPERATING

201

▫ Trailer Towing — Hitches . . . . . . . . . . . . . . . 275
▫ Connecting Trailer Lighting And Electric

Trailer Brakes . . . . . . . . . . . . . . . . . . . . . . . . 276

▫ Trailer Weight And Trailer Tongue Weight . . . . 278
▫ Trailer Towing Information

(Maximum Trailer Weight Ratings) . . . . . . . . . 279

▫ Trailer Towing Mirrors — If Equipped . . . . . . 279
▫ Cooling System Tips — Trailer Towing . . . . . . 280
▫ Automatic Transmission Oil Temperature

Warning Light . . . . . . . . . . . . . . . . . . . . . . . 281

▫ Towing With An Automatic Transmission . . . . 281

m Snowplow . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282

▫ Before Plowing . . . . . . . . . . . . . . . . . . . . . . . 283
▫ Snowplow Prep Package Model Availability . . 283

▫ Over The Road Operation With Snowplow

Attached . . . . . . . . . . . . . . . . . . . . . . . . . . . 284

▫ Methods For Removing Snow . . . . . . . . . . . . 284
▫ Operating Tips . . . . . . . . . . . . . . . . . . . . . . . 284
▫ General Maintenance . . . . . . . . . . . . . . . . . . . 285

m Recreational Towing — 4–Wheel Drive Vehicles

(Behind Motorhome, Etc.) . . . . . . . . . . . . . . . . . 286

▫ Recreational Towing Procedure — Manual

Shift Transfer Case — If Equipped . . . . . . . . . 286

▫ Returning To Normal Operation — Manual

Shift Transfer Case . . . . . . . . . . . . . . . . . . . . 287

▫ Recreational Towing Procedure — Electronic

Shift Transfer Case — If Equipped . . . . . . . . . 288

▫ Returning To Normal Operation — Electronic

Shift Transfer Case . . . . . . . . . . . . . . . . . . . . 290

202

STARTING AND OPERATING

IGNITION/STARTER SWITCH

LOCK

Locks the automatic transmission shift control into the
PARK position. It also engages the steering wheel lock (if
equipped) when the steering wheel is turned.

NOTE:

This vehicle is equipped with a transmission

shift interlocking system. The brake pedal must be
depressed to shift out of Park (P).

OFF

Unlocks the steering wheel (if equipped with locking
wheel) and the automatic transmission shift control with
engine off.

This is the normal running position.

START

Starts the engine. When the engine starts, release the key.
The ignition key will return to the ON position for
normal driving.

204

STARTING AND OPERATING

ACC

Allows the electrical accessories to be used when the
engine is not running.

Manual Transmission Key Release Button

To remove the key on vehicles equipped with manual
transmissions, turn the key to the Lock position and press
the button to remove the ignition key.

Key Reminder

An alarm will sound to remind you if the key is left in the
ignition and the driver’s door is opened.

STARTING PROCEDURES

The Cummins Diesel engine is equipped with several
features designed to assist cold weather starting and
operation:

• The engine block heater is a resistance heater installed

in the water jacket of the engine just above and behind
the oil filter. It requires a 110–115 volt AC electrical
outlet with a grounded, three-wire extension cord.

NOTE:

The engine block heater cord is a factory in-

stalled option. If your vehicle is not equipped, heater
cords are available from your authorized Mopar

t dealer.

• A 12–volt heater built into the fuel filter housing aids

in preventing fuel gelling. It is controlled by a built-in
thermostat.

STARTING AND OPERATING

205

• A heated intake air system both improves engine

starting and reduces the amount of white smoke
generated by a warming engine.

Normal Starting Procedure — Engine Manifold
AirTemperature Above 66°F (19°C)

Observe the Instrument Panel Cluster lights when start-
ing the engine.

1. Always apply the parking brake.

2. Shift into PARK for an automatic transmission. Fully
depress and hold the clutch and shift into NEUTRAL for
a manual transmission. Models with manual transmis-
sion are equipped with a clutch interlocking cranking
system. The clutch must be fully depressed to start the
vehicle.

3. Turn the ignition key to the ON position and look at
the instrument panel cluster lamps.

The lamps in the instrument panel cluster will illuminate
when the ignition key is first turned to the ON position.
This is a bulb check programmed to last for approxi-
mately 3 seconds. After the bulb check is completed, the
Malfunction Indicator Light and Brake Warning light will
remain on. After the bulb check is complete and the
WAIT TO START indicator goes out proceed to step 4.

CAUTION!

If WATER IN FUEL indicator light remains on DO
NOT START engine before you drain water from the
fuel filter to avoid engine damage. See Section 7 —
Maintaining Your Vehicle, for water drain proce-
dures.

4. Turn the ignition key to START and crank the engine.
Do not press the accelerator during starting.

206

STARTING AND OPERATING

CAUTION!

Do not crank engine for more than 15 seconds at a
time as starter motor damage may result. Turn key to
OFF and wait at least two minutes before trying
again.

5. When the engine starts, release the key.

6. Check to see that there is oil pressure.

7. Release the parking brake.

Starting Procedure — Engine Manifold Air
Temperature Below 66°F (19°C)

NOTE:

The temperature displayed on the overhead

console (if equipped) does not necessarily reflect the
engine manifold air temperature. The wait-to-start lamp
will illuminate momentarily for a bulb check when the
ignition key is turned to the ON position, however when

certain engine temperatures fall below 66°F (19°C) the
lamp will remain on indicating the intake manifold
heater system is active.

Follow the steps in the Normal Starting Procedure ex-
cept:

CAUTION!

Do not crank engine for more than 15 seconds at a
time or starter motor damage may result. Turn key to
OFF and wait at least 2 minutes for starter to cool
before repeating start procedure.

• The WAIT TO START light will remain on for a period

of time (length of time depends on engine tempera-
ture) after completion of the bulb check.

STARTING AND OPERATING

207

• After the WAIT TO START light goes off, turn the

ignition key to START. Do not press the accelerator
during starting.

• Check to see that there is oil pressure.
• Allow the engine to idle at fast idle for about three

minutes until the manifold heaters have completed
the post-heat cycle.

• Release the parking brake and drive.

NOTE:

Engine idle speed will automatically increase to

1000 rpm at low coolant temperatures to improve engine
warm-up.

NOTE:

If the engine stalls or if the ignition switch is left

On for more than 2 minutes after the WAIT TO START
light goes out, reset the grid heaters by turning the
ignition switch to Off and the back On. Repeat steps 3
through 7 of the normal starting procedure.

For Extremely Cold Weather Starting (Engine
Temperature Below 0°F (- 18°C)
In extremely cold weather below 0°F (- 18°C) it may be
beneficial to cycle the manifold heaters twice before
attempting to start the engine. This can be accomplished
by turning the ignition OFF and then back ON after the
WAIT TO START light has gone off, but before the engine
is started. However, repeated cycling of the manifold
heaters will result in damage to the heater elements or
reduced battery voltage.

NOTE:

If multiple pre-heat cycles are used before

starting, additional engine run time may be required to
maintain battery state of charge at a satisfactory level.

• If the engine stalls after the initial start, the ignition

must be turned to the OFF position and then to the ON
position to recycle the manifold heaters.

NOTE:

Excessive white smoke and poor engine perfor-

mance will result if manifold heaters are not recycled.

208

STARTING AND OPERATING

• Heat generated by the manifold heaters dissipates

rapidly in a cold engine. If more than two minutes
pass between the time the WAIT TO START light goes
OFF and the engine is started, recycle the manifold
heaters by turning the ignition OFF and then back ON.

• If the vehicle is driven and vehicle speed exceeds 18

mph (29 km) before the manifold heater post-heat
(after start) cycle is complete, the manifold heaters will
shut off.

• If the engine is started before the WAIT TO START

light turns off, the preheat cycle will turn off.

• If the engine is cranked for more than 10 seconds, the

post-heat cycle will turn off.

NOTE:

Engine idle speed will automatically increase to

1000 rpm at low coolant temperatures to improve engine
warm-up.

NOTE:

When a diesel engine is allowed to run out of

fuel or the fuel gels at low temperatures, air is pulled into
the fuel system.

You may try priming as described below.

1. Add a substantial quantity of fuel to the tank (5 to 10
gallons) or eliminate the gelled fuel condition.

2. Crank the engine for 1 to 2 seconds. If the engine does
not start, then release the key or starter button back to the
RUN position (do not turn the key back to the OFF
position). The electric fuel transfer pump will continue to
run and purge air from the system for about 25 seconds.
After 25 seconds, attempt to start the engine again.

3. Start the engine using the Normal Starting Procedure.

4. Repeat the procedure if the engine does not start.

STARTING AND OPERATING

209

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.

NOTE:

The engine may run rough until the air is forced

from all the fuel lines.

Starting Fluids

WARNING!

STARTING FLUIDS or flammable liquids are
NEVER TO BE USED in the Cummins Diesel (see
Warning label). Never pour diesel fuel, flammable
liquid, starting fluids (ether) into the air cleaner
canister, air intake piping, or turbocharger inlet in an
attempt to start the vehicle. This could result in a
flash fire and explosion causing serious personal
injury and engine damage.

The engine is equipped with an automatic electric air
preheating system. If the instructions in this manual are
followed, the engine should start in all conditions.

210

STARTING AND OPERATING

WARNING!

Do not leave children or animals inside parked
vehicles in hot weather. Interior heat build up may
cause serious injury or death.

NORMAL OPERATION

Observe the following when the engine is operating.

• All message center lights are off.
• Check Engine Lamp is off.
• Engine Oil Pressure is above 10 psi (69 kPa) at idle.
• Low Oil Pressure light is off.
• Voltmeter Operation:

• The voltmeter may show a gauge fluctuation if

certain engine temperatures are below 66°F (19°C).
This cycling operation is caused by the post-heat

cycle of the intake manifold heater system. The
number of cycles and the length of the cycling
operation is controlled by the engine control mod-
ule, this time will not exceed 150 seconds. The
needle should then stabilize at the approximate
operation point.

• The cycling action will cause temporary dimming of

the headlamps, interior lamps, and also a noticeable
reduction in blower motor speed.

Cold Weather Precautions

Operation in ambient temperature below 32°F (0°C) may
require special considerations. The following charts sug-
gest these options:

STARTING AND OPERATING

211

Dodge Diesel (2004 year). Manual - part 13