Dodge 5500 Chassis Cab (2008 year). Instruction

Engine Oil Selection (Gas Engines)
For best performance and maximum protection under all
types of operating conditions, the manufacture only
recommends engine oils that are API certified and meet
the requirements of DaimlerChrysler Material Standard
MS-6395. Use Mopar or an equivalent oil meeting the
specification MS-6395.

American Petroleum Institute (API) Engine Oil
Identification Symbol

This symbol means that the oil has
been certified by the American
Petroleum Institute (API). The
manufacture only recommends
API Certified engine oils.

Engine Oil Viscosity (SAE Grade)
For trucks with a 5.7L engine operating under a gross
combined weight rating of 14,000 lbs or greater, SAE
5W-30 engine oil is recommended for all operating
temperatures. For all other trucks with a 5.7L engine,
operating under a gross weight rating less than 14,000
lbs SAE 5W-20 engine oil is recommended for all
operating temperatures. These engine oils improve low
temperature starting and vehicle fuel economy. Your
engine oil filler cap also shows the recommended
engine oil viscosity for your vehicle.

For information on engine oil filler cap location, see the
Engine Compartment illustration in this section.

Lubricants which do not have both, the engine oil certi-
fication mark and the correct SAE viscosity grade num-
ber should not be used.

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MAINTAINING YOUR VEHICLE

Change Engine Oil (Diesel Engines)
Follow the Diesel Maintenance Schedule for recom-
mended engine oil change intervals.

Engine Oil Selection (Diesel Engines)
For best performance and maximum protection under all
types of operating conditions, the manufacture only
recommends engine oils that are API CJ-4 certified and
meet the requirements of DaimlerChrysler. Use Mopar or
an equivalent oil meeting the specification MS-10902.
Products meeting Cummins CES 20081 may also be used.
The identification of these engine oils are typically lo-
cated on the back of the oil container.

American Petroleum Institute (API) Engine Oil
Identification Symbol

This symbol means that the oil has
been certified by the American Petro-
leum Institute (API). The manufacture
only recommends API Certified en-
gine oils.

Oils with a high ash content may produce deposits on
valves that can progress to guttering and valve burning.
A maximum sulfated ash content of 1.00 mass % is
recommended for all oil used in the engine.

The same oil change interval is to be followed for
synthetic oil as for petroleum based oil. Also, synthetic oil
must meet the same performance specifications as petro-
leum oil.

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409

Engine Oil Viscosity (SAE Grade)
Use

SAE

15W-40

Engine

Oil

that

meets

DaimlerChrysler Materials Standard MS-10902 and the
API CJ-4 engine oil category.

Engine oil not designated by the DaimlerChrysler or
Cummins Material Standards and API CJ-4 should not be
used, engine and exhaust system durability may be
compromised. For lower temperature operation SAE
5W-40 engine oils may be used. These oils must meet the
same requirements as stated previously. Your engine oil
filler cap also shows the recommended engine oil viscos-
ity for your vehicle.

Synthetic Engine Oils
You may use synthetic engine oils provided the recom-
mended oil quality requirements are met, and the recom-
mended maintenance intervals for oil and filter changes
are followed.

Materials Added to Engine Oil
The manufacture strongly recommends against the addi-
tion of any additives (other than leak detection dyes or
lube odorants) to the engine oil. Engine oil is an engi-
neered product and it’s performance may be impaired by
supplemental additives.

NOTE:

The manufacturer offers a lube odorant (Mopar

Diesel Fresh) for diesel engines crankcases. The lube
odorant is recommended by the manufacturer to reduce
the sulfur smell that may occur during engine idling.

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

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MAINTAINING YOUR VEHICLE

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

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 instal-
lation. 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.

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

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411

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
engine. Choose the correct oil for your operating condi-
tions as outlined in the Selection of Engine Oil.

Fill the engine with the correct grade of new oil.

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

Run the engine until it has reached operating tempera-
ture, 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.

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.

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Drive Belts (Gas Engines)

Belt tension is controlled by means of an automatic
tensioner. No belt tension adjustments are required.
However, belt and belt tensioner condition should be
inspected at the specified intervals and replaced if re-
quired. See your authorized dealer for service.

At the mileage indicated in the maintenance schedule, all
belts and tensioner should be checked for condition.
Improper belt tension can cause belt slippage and failure.

Belts should be inspected for evidence of cuts, cracks,
glazing or frayed cords and replaced if there is indication
of damage which could result in belt failure. Low gen-
erator belt tension can cause battery failure.

Also check belt routing to make sure there is no interfer-
ence between the belts and other engine components.

Drive Belt (Diesel Engines)

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 (Gas Engines)

Follow the appropriate Maintenance Schedule for recom-
mended Air Cleaner Replacement intervals.

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413

WARNING!

The air induction system (air cleaner, hoses, etc) can
provide a measure of protection in the case of engine
backfire. Do not remove the air induction system (air
cleaner, hoses, etc) unless such removal is necessary
for repair or maintenance. Make sure that no one is
near the engine compartment before starting the
vehicle with the air induction system (air cleaner,
hoses, etc) removed. Failure to do so can result in
serious personal injury.

Engine Air Cleaner Filter (Diesel Engines)

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.

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

NOTE:

The air filter housing contains a Mass Air Flow

sensor. This sensor is critical to proper engine operation
and component longevity. Any damage or modification

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to this sensor could result in major engine and/or
exhaust aftertreatment damage. This includes the use of
non-approved air filters. Use only MOPAR

t approved air

filters or equivalent.

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.

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415

• If the filter is not damaged, remove all snow/ice,

reinstall filter and reset the Filter Minder™.

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.

CAUTION!

Many aftermarket performance air filter elements do
not adequately filter the air entering the engine. Use
of such filters can severely damage your engine.

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MAINTAINING YOUR VEHICLE

Draining Fuel/Water Separator Filter (Diesel
Engines)

CAUTION!

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

CAUTION!

Do not prefill the fuel filter when installing a new
fuel filter. There is a possibility debris could be
introduced into the fuel filter during this action. It is
best to install the filter dry and allow the in-tank lift
pump to prime the fuel system.

NOTE:

The fuel filter and water separator assembly is

located on the driver’s side of the engine. The best access
to the water drain valve is through the driver’s side
wheel well.

NOTE:

Care should be taken in disposing of used fluids

from your vehicle. Used fluids, indiscriminately dis-
carded, can present a problem to the environment. Con-
tact your local dealer, service station, or government

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417

agency for advice on recycling programs and for where
used fluids and filters can be properly disposed of in
your area.

Drain a small amount from the fuel/water separator
filter monthly or when the WATER IN FUEL indicator
lamp is on. Turn the drain valve, located on the bottom of
the filter, counterclockwise and allow any accumulated
water to drain. Leave the drain valve open until all water
and contaminants have been removed. Close the drain
valve, by turning it clockwise, when clean fuel is visible.

NOTE:

The Fuel / Water separator drain valve is

located on the bottom 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.”

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.

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MAINTAINING YOUR VEHICLE

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.

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.

CAUTION!

Due to lack of lubricants in alcohol or gasoline, the
use of these fuels can cause damage to the fuel
system.

NOTE:

A maximum blend of 5% biodiesel, meeting

ASTM specification D-6751 may be used with your
Cummins Diesel equipped vehicle. Use of bio-diesel

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419

mixture in excess of 5% can negatively impact the on-
engine fuel filter’s ability to separate water from the fuel,
resulting in high pressure fuel system corrosion or dam-
age.

NOTE:

As sufficient testing has not been completed,

ethanol blends are not recommended or approved for use
with your Cummins Diesel equipped vehicle.

NOTE:

In addition, commercially available fuel addi-

tives are not necessary for the proper operation of your
Cummins Diesel equipped vehicle.

Engine Fuel Filter (Gas Engines)

A plugged fuel filter can cause stalling, limit the speed at
which a vehicle can be driven or cause hard starting.
Should an excessive amount of dirt accumulate in the
fuel tank, frequent filter replacement may be necessary.

Spark Plugs (Gas Engines)

Spark plugs must fire properly to assure engine perfor-
mance and emission control. New plugs should be in-
stalled at the specified mileage. The entire set should be
replaced if there is any malfunction due to a faulty spark
plug, malfunctioning spark plugs can damage the cata-
lytic converter. For proper type of replacement spark
plugs, refer to the Fluids, Lubricants and Genuine Parts
section in this instruction.

Catalytic Converter (Gas Engines)

The catalytic converter requires the use of unleaded fuel
only. Leaded gasoline will destroy the effectiveness of the
catalyst as an emission control device.

Under normal operating conditions, the catalytic con-
verter will not require maintenance. However, it is im-
portant to keep the engine properly tuned to assure
proper catalyst operation and prevent possible catalyst
damage.

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CAUTION!

Damage to the catalytic converter can result if your
vehicle is not kept in proper operating condition. In
the event of engine malfunction, particularly involv-
ing engine misfire or other apparent loss of perfor-
mance, have your vehicle serviced promptly. Contin-
ued operation of your vehicle with a severe
malfunction could cause the converter to overheat,
resulting in possible damage to the converter and the
vehicle.

NOTE:

Intentional tampering with emissions control

systems can result in civil penalties being assessed
against you.

WARNING!

A hot exhaust system can start a fire if you park over
materials that can burn. Such materials might be
grass or leaves coming into contact with your exhaust
system. Do not park or operate your vehicle in areas
where your exhaust system can contact anything that
can burn.

In unusual situations involving grossly malfunctioning
engine operation, a scorching odor may indicate severe
and abnormal catalyst overheating. If this occurs, the
vehicle should be stopped, the engine shut off and the
vehicle allowed to cool. Thereafter, service, including a
tune-up to manufacturer’s specifications, should be ob-
tained immediately.

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421

To minimize the possibility of catalyst damage:

• Do not shut off the engine or interrupt the ignition

when the transmission is in gear and the vehicle is in
motion.

• Do not try to start engine by pushing or towing the

vehicle.

• Do not idle the engine with any spark plug wires

disconnected or removed, such as when diagnostic
testing, or for prolonged periods during very rough
idling or malfunctioning operating conditions.

Intervention Regeneration Strategy – EVIC
Message Process Flow (Catalyst Full Message)
(Diesel Engines Only)

Your new Cummins 6.7L diesel meets all EPA Heavy
Duty Diesel Engine Emissions Standards, resulting in the
lowest emitting diesel engine ever produced.

To achieve these emission standards your vehicle is
equipped with state of the art engine and exhaust system.
The engine and exhaust aftertreatment system work
together to achieve the EPA Heavy Duty Diesel Engine
Emissions Standards. These systems are seamlessly inte-
grated into your vehicle and managed by the Cummins
6.7L engine Powertrain Control Module (PCM). The PCM
manages engine combustion to allow the exhaust sys-
tem’s catalyst to trap and burn Particulate Matter (PM)
pollutants, with no input or interaction on your part.

Additionally, the overhead console in your vehicle has
the ability to alert you to additional maintenance re-
quired on your truck or engine. Refer to the following
messages that may be displayed on your Electronic
Vehicle Information Center (EVIC):

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WARNING!

Service CCV Filter
The 6.7L Cummins engine utilizes a Closed Crankcase
Ventilation (CCV) system. This system filters and recycles
gasses produced in the crankcase during the normal
combustion process. Service CCV Filter will be displayed
on the overhead console of your Dodge truck if the CCV
filter is due for required maintenance. This filter is
located on the top of the engine valve cover. For addi-
tional information, see your Dodge truck dealer.

Catalyst Full See Owner Instruction
Catalyst Full See Owner Instruction will be displayed on the
overhead console of your vehicle if the exhaust particu-
late filter reaches 80% of its maximum storage capacity.
Under conditions of exclusive short duration and low
speed driving cycles, your Cummins engine and exhaust
aftertreatment system may never reach the conditions
required to remove the trapped PM, if this occurs Cata-
lyst Full See Owner Manual will be displayed on the
overhead console in your vehicle. If this message is
displayed you will hear one chime to assist in alerting
you of this condition.

Catalyst Stat::::::::::80%
Catalyst Stat::::::::::80% will replace the message Catalyst
Full See Owner Instruction after it is displayed for one
minute. The engine Powertrain Control Module (PCM)
will continue to monitor the amount of particulate matter

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Dodge 5500 Chassis Cab (2008 year). Instruction - part 26