Dodge Diesel (2004 year). Manual

• 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.

• If 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.

• To avoid burns, remember that the engine components

will stay hot after the engine is shut off.

• Do not use gasoline or other flammable materials to

clean parts. Always use approved cleaning solvents.

• Relieve 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 utilizes

pressure. 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.

• Important: All maintenance other than that listed in

this manual, as well as some procedures listed here,
MUST

be performed by your local Dodge Truck

Dealer. Your authorized Dodge Dealer has been
trained and has the necessary parts to maintain your
engine.

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MAINTAINING YOUR VEHICLE

MAINTENANCE PROCEDURES

The pages that follow contain the required maintenance
services determined by the engineers who designed your
vehicle.

Besides the maintenance items for which there are fixed
maintenance intervals, there are other items that should
operate satisfactorily without periodic maintenance.
However, if a malfunction of these items does occur, it
could adversely affect the engine or vehicle performance.
These items should be inspected if a malfunction is
observed or suspected.

Engine Oil

Checking Oil Level
To assure proper lubrication of your vehicle’s engine, the
engine oil must be maintained at the correct level. Check
the oil level at regular intervals. The best time to check
the oil level is before starting the engine after it has been
parked overnight. When checking oil after operating the
engine, first ensure the engine is at full operating tem-
perature, then wait at least 15 minutes after engine
shutdown to check the oil.

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325

Checking the vehicle while it’s on level ground will also
improve the accuracy of the oil level readings. Add oil
only when the level on the dipstick is below the “ADD”
mark. The total capacity from the low mark to the high
mark is 2 quarts (1.9 liters).

Never operate the engine with oil level below the “ADD”
mark or above the upper “SAFE” mark.

Change Engine Oil

CAUTION!

Overfilling or underfilling the crankcase will cause
oil aeration or loss of oil pressure. This could dam-
age your engine.

Road conditions as well as your kind of driving affect the
interval at which your oil should be changed. Check the
following to determine if any apply to you:

• Frequent short trips where the engine does not achieve

full operating temperature (operating temperature de-
fined as 190° F (66° C ) coolant temperature).

• Extensive engine idling (over 10 minutes per hour of

operation) at ambient temperatures less than 32° F (0°
C).

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MAINTAINING YOUR VEHICLE

• Driving in dusty conditions.
• Frequent trailer towing.
• Taxi, police, or delivery service (commercial service).
• Off-road or desert operation.
• Extensive operation at high engine speeds (greater

than 2900 rpm) and loads (greater than 70% throttle).

If ANY of these apply to you, then change your engine oil
at every interval shown in schedule

9B9 of the 9Mainte-

nance Schedules

9 section of this manual.

If none of these apply to you, then change your engine oil
at every interval shown on schedule

9A9 of the 9Mainte-

nance Schedules

9 section of this manual.

NOTE:

Most vehicles are operated under the conditions

listed for Schedule

9B.9

Engine Oil Selection

1. Engine Oil Quality

Use only oils conforming to API
Service CI-4. A sulfated ash limit
is specified for lubrication oil used
in Cummins engines. Oils with a
high ash content may produce de-
posits on valves that can progress
to guttering and valve burning. A
maximum sulfated ash content of
1.85 mass % is recommended for
all oil used in the engine.

2. Engine Oil Viscosity (SAE Grade)
The proper SAE viscosity of engine oil for the expected
ambient temperature range should be selected, as indi-
cated in the following chart:

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327

NOTE:

The same oil change interval is to be followed

for synthetic oil as for petroleum based oil. Also, syn-
thetic oil must meet the same performance specifications
as petroleum oil.

Engine Oil Filter
Refer to Recommended Fluids, Lubricants and Genuine
Parts for the correct part number. The engine oil filter
should be changed at every engine oil change.

Engine Oil And Filter — Change

WARNING!

Hot oil can cause personal injury.

Operate the engine until the coolant temperature reaches
140°F (60°C). Shut the engine off. Remove the oil drain
plug.

Use a container that can hold at least 12 quarts (11.3
Liters) to hold the used oil.

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MAINTAINING YOUR VEHICLE

Always check the condition of the used oil. This can give
you an indication of some engine problems that might
exist.

• Thin, black oil indicates fuel dilution.
• Milky 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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329

Apply a light film of lubricating oil to the sealing surface
of the filter gasket before installing the filter.

CAUTION!

Overtightening may distort the threads or damage
the filter element seal.

Install the filter as specified by the filter manufacturer.
Turn the filter 3/4 to one full turn after making contact
with the gasket.

Check the condition of the threads and sealing surface on
the oil pan and drain plug.

Install the drain plug and sealing washer and tighten to
37 ft-lbs. (50 N·m).

Use only high-quality multi-grade lubricating oil in your
Cummins Diesel Engine. Choose the correct oil for your
operating conditions as outlined in the Selection of
Engine Oil.

Cummins Turbo Diesel

Fill the engine with the correct grade of new oil. The
engine capacity is 11 quarts (10.4 liters) in the crankcase
and 1 quart (.95 liter) in the lubricating oil filter.

Start the engine and operate it at idle for several minutes.
Check for leaks at the lubricating oil filter and oil pan
drain plug.

Stop the engine. Wait approximately 15 minutes to let the
oil in the upper parts of the engine drain back to the pan.
Check the oil level again.

Add oil as necessary to bring the level to the “SAFE”
mark on the dipstick.

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Disposing Of Used Engine Oil And Filter
Care should be taken in disposing of the used engine
fluids from your vehicle. Used fluids, indiscriminately
discarded, can present a problem to the environment.
Contact your local dealer, service station, or governmen-
tal agency for advice on recycling programs and where
used fluids and filters can be safely discarded in your
area.

Drive Belt

Inspection
Check the belt for intersecting cracks.

• Transverse (across the belt width) cracks are accept-

able.

• Longitudinal (direction of belt length) cracks that

intersect with transverse cracks are NOT acceptable.

Replace the belt if it has unacceptable cracks, is frayed or
has pieces of material missing.

The engine speed sensor, located near the damper, should
be inspected for damage if a belt is frayed.

Engine Air Cleaner Filter

CAUTION!

All air entering the engine intake must be filtered.
The abrasive particles in unfiltered air will cause
rapid wear to engine components.

The air filter housing on your Diesel Ram is equipped
with a Filter Minder™. This is an air flow restriction
gauge that will indicate when the filter element needs to
be replaced.

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331

Do not remove the top of the air filter housing to
inspect the filter element on your diesel engine under
normal operating conditions.

The clear plastic housing on the Filter Minder™ allows
you to view the amount of air pressure drop across the
filter element. It consists of a diaphragm and a calibrated
spring sealed inside the plastic housing. As the air

cleaner filter becomes clogged and air pressure drop
across the filter element increases, a yellow disc travels
along a graduated scale on the side of the Filter
Minder™.

The yellow disc will always show the greatest restriction
experienced by the filter element. When the disc reaches
the red zone, the filter element may need to be replaced.
There is no other time or mileage interval for changing
the air cleaner filter element.

If the vehicle experiences a sudden loss of engine power
when being driven in heavy snow or rain or when
plowing snow, check the Filter Minder™

• If the Filter Minder™ is showing a plugged filter, the

filter should be visually inspected for snow/ice build
up or extreme water saturation.

• If any of these conditions exist, the filter element

should be replaced.

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MAINTAINING YOUR VEHICLE

A visual inspection of the air cleaner filter element is
never recommended under normal circumstances. A
badly restricted element may appear clean while a soiled
element may be quite effective in filtering particles
without restricting air flow. Rely on the Filter Minder™
to determine when a filter change is necessary.

After a new filter element is inserted, press the rubber
button on the top of the Filter Minder™. This action will
reset the yellow disc to the clean position.

CAUTION!

When using an engine cleaner or a degreaser, be sure
to wrap and tape the Filter Minder™ to protect the
plastic housing from damage and discoloration.

NOTE:

Many aftermarket performance air filter ele-

ments do not adequately filter the air entering the engine.
Use of such filters can severely damage your engine and
such damage is not covered by the manufacturer’s war-
ranty.

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333

Draining Fuel/Water Separator Filter

CAUTION!

Do not drain the fuel/water separator filter when the
engine is running.

Drain a small amount from the fuel/water separator
filter periodically or when the WATER IN FUEL indicator
lamp is on. Pull outward on the drain valve lever, located
on the side of the filter, and allow any accumulated water
to drain. Hold the drain valve open until all water and
contaminants have been removed. Close the drain release
valve, by returning it to the inward position, when clean
fuel is visible.

NOTE:

The Fuel / Water separator drain valve is

identified by its yellow handle and is located on the
inboard side of the fuel filter housing.

If more than a couple ounces of fuel has been drained,
follow the directions below for “Priming if the engine has
run out of fuel.”

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MAINTAINING YOUR VEHICLE

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.

Priming if the engine has run out of fuel

1. Add a substantial quantity of fuel to the tank 5 to 10
gallons (19L to 38L).

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.

CAUTION!

Do not engage the starter motor for more than 15
seconds at a time. Allow two minutes between the
cranking intervals.

NOTE:

The engine may run rough until the air is forced

from all the fuel lines.

CAUTION!

Diesel fuel will damage black top paving surfaces.
Drain the filter into an appropriate container.

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335

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.

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MAINTAINING YOUR VEHICLE

To determine the battery charge, check the battery test
indicator (if equipped) on top of each battery. If the test
indicator (if equipped) appears light or yellow, replace
the battery.

NOTE:

Replacement batteries should both be of equal

capacity to prevent damage to the vehicle’s charging
system.

CAUTION!

It is essential when replacing the cables on the
battery that the positive cable is attached to the
positive post and the negative cable is attached to the
negative post. Battery posts are marked (+) positive
and negative (-) and identified on the battery case.
Also, if a “fast charger” is used while battery is in
vehicle, disconnect both vehicle battery cables be-
fore connecting the charger to battery. Do not use a
“fast charger” to provide starting voltage.

WARNING!

Battery posts, terminals, and related accessories con-
tain lead and lead compounds. Always wash hands
after handling the battery.

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337

Battery Blanket Usage
A battery loses 60% of its cranking power as the battery
temperature decreases to 0°F (-18°). For the same de-
crease in temperature, the engine requires twice as much
power to crank at the same RPM. The use of 120 VAC
powered battery blankets will greatly increase starting
capability at low temperatures. Suitable battery blankets
are available from your authorized Mopar

t dealer.

Air Conditioner Maintenance

For best possible performance, your air conditioner
should be checked and serviced by an Authorized Dealer
at the start of each warm season. This service should
include cleaning of the condenser fins and a performance
test. Drive belt tension should also be checked at this
time.

WARNING!

• Use only refrigerants and compressor lubricants

approved by the manufacturer for your air condi-
tioning system. Some unapproved refrigerants are
flammable and can explode, injuring you. Other
unapproved refrigerants or lubricants can cause
the system to fail, requiring costly repairs.

• The air conditioning system contains refrigerant

under high pressure. To avoid risk of personal
injury or damage to the system, adding refrigerant
or any repair requiring lines to be disconnected
should be done by an experienced repairman.

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Refrigerant Recovery and Recycling
R-134a Air Conditioning Refrigerant is a hydrofluorocar-
bon (HFC) that is endorsed by the Environmental Pro-
tection Agency and is an ozone-saving product. How-
ever, the manufacturer recommends that air conditioning
service be performed by dealers or other service facilities
using recovery and recycling equipment.

NOTE:

Air Conditioning systems found to be contami-

nated with A/C System Sealers, Stop Leak Products, Seal
Conditioners, Compressor Oil, or Refrigerants not ap-
proved by the manufacturer, voids the warranty for the
Air Conditioning system.

Power Steering — Fluid Check

Checking the power steering fluid level at a defined
service interval is not required. The fluid should only be
checked if a leak is suspected, abnormal noises are

apparent, and/or the system is not functioning as antici-
pated. Coordinate inspection efforts through a certified
DaimlerChrysler Dealership.

WARNING!

Fluid level should be checked on a level surface and
with the engine off to prevent injury from moving
parts and to insure accurate fluid level reading. Do
not overfill. Use only manufacturers recommended
power steering fluid.

If necessary, add fluid to restore to the proper indicated
level. With a clean cloth, wipe any spilled fluid from all
surfaces. Refer to Recommended Fluids, Lubricants, and
Genuine Parts for correct fluid type.

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Dodge Diesel (2004 year). Manual - part 21