Dodge 2500 (2009 year). Instruction

ONBOARD DIAGNOSTIC SYSTEM (OBD II)
Your vehicle is equipped with a sophisticated onboard
diagnostic system called OBDII. This system monitors
the performance of the emissions, engine, and automatic
transmission control systems. When these systems are
operating properly, your vehicle will provide excellent
performance and fuel economy, as well as engine emis-
sions well within current government regulations.

If any of these systems require service, the OBD II system
will turn on the Malfunction Indicator Light (MIL). It will
also store diagnostic codes and other information to
assist your service technician in making repairs. Al-
though your vehicle will usually be drivable and not
need towing, see your authorized dealer for service as
soon as possible.

CAUTION!

• Prolonged driving with the MIL on could cause

further damage to the emission control system. It
could also affect fuel economy and drivability. The
vehicle must be serviced before any emissions
tests can be performed.

• If the MIL is flashing, severe catalytic converter

damage and power loss will soon occur. Immedi-
ate service is required.

Loose Fuel Filler Cap Message

If the vehicle’s diagnostic system determines that the fuel
filler cap in loose, improperly installed, or damaged, a
GASCAP message will be displayed in the instrument
cluster. Tighten the gas cap until a “clicking” sound is
heard. This is an indication that the gas cap is properly
tightened. Press the odometer reset button to turn the
message off. If the problem persists, the message will

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appear the next time the vehicle is started. This might
indicate a damaged cap. If the problem is detected twice
in a row, the system will turn on the MIL. Resolving the
problem will turn the MIL light off.

EMISSIONS INSPECTION AND MAINTENANCE
PROGRAMS
In some localities, it may be a legal requirement to pass
an inspection of your vehicle’s emissions control system.
Failure to pass could prevent vehicle registration.

For states that require an Inspection and Mainte-
nance (I/M), this check verifies the Malfunction
Indicator Light (MIL) is functioning and is not on

when the engine is running, and that the OBD II system
is ready for testing.

Normally, the OBD II system will be ready. The OBD II
system may not be ready if your vehicle was recently

serviced, recently had a dead battery or a battery replace-
ment. If the OBD II system should be determined not
ready for the I/M test, your vehicle may fail the test.

Your vehicle has a simple ignition key-actuated test,
which you can use prior to going to the test station. To
check if your vehicle’s OBD II system is ready, you must
do the following:

1. Insert your ignition key into the ignition switch.

2. Turn the ignition to the ON position, but do not crank
or start the engine.

3. If you crank or start the engine, you will have to start
this test over.

4. As soon as you turn your key to the ON position, you
will see the MIL symbol come on as part of a normal bulb
check.

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429

5. Approximately 15 seconds later, one of two things will
happen:

a. The MIL will flash for about 10 seconds and then
return to being fully illuminated until you turn OFF
the ignition or start the engine. This means that your
vehicle’s OBD II system is not ready and you should
not

proceed to the I/M station.

b. The MIL will not flash at all and will remain fully
illuminated until you turn OFF the ignition or start the
engine. This means that your vehicle’s OBD II system
is ready and you can proceed to the I/M station.

If your OBD II system is not ready, you should see your
authorized dealer or repair facility. If your vehicle was
recently serviced or had a battery failure or replacement,
you may need to do nothing more than drive your
vehicle as you normally would in order for your OBD II
system to update. A recheck with the above test routine
may then indicate that the system is now ready.

Regardless of whether your vehicle’s OBD II system is
ready or not, if the MIL is illuminated during normal
vehicle operation you should have your vehicle serviced
before going to the I/M station. The I/M station can fail
your vehicle because the MIL is on with the engine
running.

REPLACEMENT PARTS
Use of genuine MOPAR

威 parts for normal/scheduled

maintenance and repairs is highly recommended to en-
sure the designed performance. Damage or failures
caused by the use of non-MOPAR

威 parts for maintenance

and repairs will not be covered by the manufacturer’s
warranty.

DEALER SERVICE
Your authorized dealer has the qualified service person-
nel, special tools and equipment to perform all service
operations in an expert manner. Service Instructions are
available which include detailed service information for

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your vehicle. Refer to these instructions before attempting
any procedure yourself.

NOTE:

Intentional tampering with emissions control

systems can result in civil penalties being assessed
against you.

WARNING!

You can be badly injured working on or around a
motor vehicle. Do only that service work for which
you have the knowledge and the proper equipment.
If you have any doubt about your ability to perform
a service job, take your vehicle to a competent
mechanic.

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. The
best time to check the engine oil level is about five
minutes after a fully warmed up engine is shut off or
before starting the engine after it has sat overnight.

Checking the oil while the vehicle is on level ground will
improve the accuracy of the oil level readings. Always
maintain the oil level within the SAFE zone on the

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431

dipstick. Adding one quart of oil when the reading is at
the bottom of the SAFE zone will result in a reading at the
top of the safe zone on these engines.

CAUTION!

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

Change Engine Oil
Refer to the “Maintenance Schedule” in Section 8 for the
proper maintenance intervals.

Engine Oil Selection
For best performance and maximum protection under all
types of operating conditions, the manufacturer only
recommends engine oils that are API Certified and meet
the requirements of Chrysler Material Standard 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
manufacturer only recommends
API Certified engine oils.

Engine Oil Viscosity (SAE Grade)
SAE 5W-20 engine oil is recommended for all operating
temperatures. This engine oil improves low temperature
starting and vehicle fuel economy. The engine oil filler
cap also shows the recommended engine oil viscosity for
your engine. For information on engine oil filler cap
location, refer to “Engine Compartment” in this section.

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NOTE:

For 2500/3500 trucks with a 5.7L engine oper-

ating under a gross combined weight rating of 14,000 lbs
(6 350 kg) or greater, SAE 5W-30 engine oil is recom-
mended for all operating temperatures.

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

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

Materials Added to Engine Oil
Do not add any supplemental materials, other than leak
detection dyes, to the engine oil. Engine oil is an engi-
neered product and its performance may be impaired by
supplemental additives.

Disposing of Used Engine Oil and Oil Filters
Care should be taken in disposing of used engine oil and
oil filters from your vehicle. Used oil and oil filters,
indiscriminately discarded, can present a problem to the
environment. Contact your authorized dealer, service
station, or governmental agency for advice on how and
where used oil and oil filters can be safely discarded in
your area.

Engine Oil Filter
The engine oil filter should be replaced at every engine
oil change.

Engine Oil Filter Selection
The manufacturer’s engines have a full-flow type oil
filter. Use a filter of this type for replacement. The quality
of replacement filters varies considerably. Only high-
quality filters should be used to assure most efficient
service. MOPAR

威 engine oil filters are a high-quality oil

filter and are recommended.

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433

Engine Air Cleaner Filter
Refer to the “Maintenance Schedule” in Section 8 for the
proper maintenance intervals.

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 Selection
The quality of replacement engine air cleaner filters
varies considerably. Only high quality filters should be

used to assure most efficient service. MOPAR

威 engine air

cleaner filters are a high quality filter and are
recommended.

Maintenance-Free Battery
The top of the maintenance-free battery is permanently
sealed. You will never have to add water, nor is periodic
maintenance required.

WARNING!

• Battery fluid is a corrosive acid solution and can

burn or even blind you. Do not allow battery fluid
to contact your eyes, skin or clothing. Do not lean
over a battery when attaching clamps. If acid
splashes in eyes or on skin, flush the area imme-
diately with large amounts of water.

(Continued)

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WARNING! (Continued)

• Battery gas is flammable and explosive. Keep

flame or sparks away from the battery. Do not use
a booster battery or any other booster source with
an output greater than 12 Volts. Do not allow cable
clamps to touch each other.

• Battery posts, terminals and related accessories

contain lead and lead compounds. Wash hands
after handling.

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 are identified on the
battery case.

• If a “fast charger” is used while the battery is in

the vehicle, disconnect both vehicle battery cables
before connecting the charger to the battery. Do
not use a “fast charger” to provide starting voltage.

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

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435

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. Refer to
Section 3 of the Warranty Information book for
further warranty information.

• 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.

NOTE:

Use only manufacturer approved A/C System

Sealers, Stop Leak Products, Seal Conditioners, Compres-
sor Oil, or Refrigerants.

Refrigerant Recovery and Recycling
R-134a air conditioning refrigerant is a hydrofluoro-
carbon (HFC) that is endorsed by the Environmental
Protection Agency (EPA) and is an ozone-saving product.
However, the manufacturer recommends that air condi-
tioning service be performed by authorized dealers or
other service facilities using recovery and recycling
equipment.

Front Prop Shaft Lubrication — 2500/3500 (4X4)
Models
Lubricate the front driveshaft grease fitting at each oil
change. Refer to the “Maintenance Schedule” in Section 8
for the proper maintenance intervals. Use MOPAR

威 Type

MS-6560 (lithium-based grease), or equivalent.

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MAINTAINING YOUR VEHICLE

Body Lubrication
Locks and all body pivot points, including such items as
seat tracks, door hinge pivot points and rollers, liftgate,
tailgate, sliding doors and hood hinges, should be lubri-
cated periodically with a lithium based grease such as
MOPAR

威 Spray White Lube to assure quiet, easy opera-

tion and to protect against rust and wear. Prior to the
application of any lubricant, the parts concerned should
be wiped clean to remove dust and grit; after lubricating
excess oil and grease should be removed. Particular
attention should also be given to hood latching compo-
nents to ensure proper function. When performing other
underhood services, the hood latch, release mechanism
and safety catch should be cleaned and lubricated.

The external lock cylinders should be lubricated twice a
year, preferably in the Fall and Spring. Apply a small
amount of a high quality lubricant such as MOPAR

威

Lock Cylinder Lubricant directly into the lock cylinder.

Windshield Wiper Blades
Clean the rubber edges of the wiper blades and the
windshield periodically with a sponge or soft cloth and a
mild nonabrasive cleaner. This will remove accumula-
tions of salt or road film.

Operation of the wipers on dry glass for long periods
may cause deterioration of the wiper blades. Always use
washer fluid when using the wipers to remove salt or dirt
from a dry windshield.

Avoid using the wiper blades to remove frost or ice from
the windshield. Keep the blade rubber out of contact with
petroleum products such as engine oil, gasoline, etc.

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437

Adding Washer Fluid
The fluid reservoir is located under the hood and should
be checked for fluid level at regular intervals. Fill the
reservoir with windshield washer solvent only (not ra-
diator antifreeze). When refilling the washer fluid reser-
voir, take some washer fluid and apply it to a cloth or
towel and wipe clean the wiper blades, this will help
blade performance.

To prevent freeze-up of your windshield washer system
in cold weather, select a solution or mixture that meets or
exceeds the temperature range of your climate. This
rating information can be found on most washer fluid
containers.

The washer fluid reservoir will hold a full gallon of fluid
when the “Low Washer Fluid Light” illuminates.

WARNING!

Commercially available windshield washer solvents
are flammable. They could ignite and burn you. Care
must be exercised when filling or working around
the washer solution.

After the engine has warmed, operate the defroster for a
few minutes to reduce the possibility of smearing or
freezing the fluid on the cold windshield. MOPAR

威 All

Weather Windshield Washer Solution, used with water as
directed on the container, aids cleaning action, reduces
the freezing point to avoid line clogging, and is not
harmful to paint or trim.

Exhaust System
The best protection against carbon monoxide entry into
the vehicle body is a properly maintained engine exhaust
system.

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MAINTAINING YOUR VEHICLE

Whenever a change is noticed in the sound of the exhaust
system, when exhaust fumes can be detected inside the
vehicle, or when the underside or rear of the vehicle is
damaged, have a competent mechanic inspect the com-
plete exhaust system and adjacent body areas for broken,
damaged, deteriorated, or mispositioned parts. Open
seams or loose connections could permit exhaust fumes
to seep into the passenger compartment. In addition,
inspect the exhaust system each time the vehicle is raised
for lubrication or oil change. Replace as required.

WARNING!

Exhaust gases can injure or kill. They contain carbon
monoxide (CO) which is colorless and odorless.
Breathing it can make you unconscious and can
eventually poison you. To avoid breathing CO, refer
to “Exhaust Gas” in the “Safety Tips” section of this
instruction.

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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439

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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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 the 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.

Cooling System

WARNING!

You or others can be badly burned by hot engine
coolant (antifreeze) or steam from your radiator. If
you see or hear steam coming from under the hood,
do not open the hood until the radiator has had time
to cool. Never try to open a cooling system pressure
cap when the radiator is hot.

Engine Coolant Checks
Check the engine coolant (antifreeze) protection every
12 months (before the onset of freezing weather, where
applicable). If the engine coolant (antifreeze) is dirty or
rusty in appearance, the system should be drained,
flushed and refilled with fresh engine coolant (anti-
freeze). Check the front of the A/C condenser for any

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441

accumulation of bugs, leaves, etc. If dirty, clean by gently
spraying water from a garden hose vertically down the
face of the condenser.

Check the coolant recovery bottle tubing for brittle rub-
ber, cracking, tears, cuts and tightness of the connection
at the bottle and radiator. Inspect the entire system for
leaks.

With the engine at normal operating temperature (but
not running), check the cooling system pressure cap for
proper vacuum sealing by draining a small amount of
engine coolant (antifreeze) from the radiator drain cock.
If the cap is sealing properly, the engine coolant (anti-
freeze) will begin to drain from the coolant recovery
bottle. DO NOT REMOVE THE COOLANT PRESSURE
CAP WHEN THE COOLING SYSTEM IS HOT.

Cooling System — Drain, Flush and Refill
If the engine coolant (antifreeze) is dirty or contains a
considerable amount of sediment, clean and flush with a
reliable cooling system cleaner. Follow with a thorough
rinsing to remove all deposits and chemicals. Properly
dispose of the old engine coolant (antifreeze) solution.

Refer to the “Maintenance Schedule” in Section 8 for the
proper maintenance intervals.

Selection Of Coolant
Use only the manufacturer’s recommended engine cool-
ant (antifreeze). Refer to “Fluids, Lubricants, and Genu-
ine Parts” in this section for the correct fluid type.

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CAUTION!

• Mixing of engine coolant (antifreeze) other than

specified HOAT engine coolant (antifreeze), may
result in engine damage and may decrease corro-
sion protection. If a non-HOAT engine coolant
(antifreeze) is introduced into the cooling system
in an emergency, it should be replaced with the
specified engine coolant (antifreeze) as soon as
possible.

• Do not use water alone or alcohol-based engine

coolant (antifreeze) products. Do not use addi-
tional rust inhibitors or antirust products, as they
may not be compatible with the radiator engine
coolant (antifreeze) and may plug the radiator.

(Continued)

CAUTION! (Continued)

• This vehicle has not been designed for use with

Propylene Glycol based engine coolant (anti-
freeze). Use of Propylene Glycol based engine
coolant (antifreeze) is not recommended.

Adding Coolant
Your vehicle has been built with an improved engine
coolant (antifreeze) that allows extended maintenance
intervals. This engine coolant (antifreeze) can be used up
to 5 Years or 102,000 miles (170 000 km) before replace-
ment. To prevent reducing this extended maintenance
period, it is important that you use the same engine
coolant (antifreeze) throughout the life of your vehicle.
Please review these recommendations for using Hybrid
Organic Additive Technology (HOAT) engine coolant
(antifreeze).

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Dodge 2500 (2009 year). Instruction - part 27