Complete minor tune-up service for the 6.7L Cummins diesel including oil and filter change, air filter replacement, fuel filter replacement, and inspection of critical engine systems.

Warnings

Tools required

Parts

• Engine oil filter × 1 — Mopar 68197867AA or equivalent
• Oil drain plug crush washer × 1 — Use OEM specification
• Engine air filter × 1 — Mopar 68157291AA or equivalent
• Primary fuel filter/water separator × 1 — Mopar 68197867AB or equivalent
• Secondary fuel filter × 1 — Mopar 68157291AB or equivalent

Fluids

• Mopar 5W-20 Synthetic Blend — 13 qt

Preparation

1. Park vehicle on level surface and engage parking brake. Place wheel chocks behind rear wheels.
2. Allow engine to cool for at least 30 minutes if recently operated to avoid burns from hot oil.
3. Raise and safely support front of vehicle using jack and jack stands to access oil drain plug.
4. Gather all tools, replacement parts, and 13 quarts of specified engine oil before beginning.
5. Have appropriate containers ready for used oil (minimum 15 quart capacity) and diesel fuel disposal.

Procedure

1. 1

   Drain engine oil
   Position drain pan under oil drain plug on bottom of oil pan. Using 19mm socket, loosen and remove oil drain plug. Allow oil to drain completely (15-20 minutes). Inspect drain plug threads and oil pan threads for damage. Discard old crush washer and install new crush washer on drain plug.
   Torque spec

   Oil Drain Plug35 Nm (26 lb-ft)
2. 2

   Remove and replace oil filter
   Locate oil filter on driver side of engine block. Position drain pan under filter. Using oil filter wrench, turn filter counterclockwise to remove. Clean filter mounting surface on engine block. Apply thin coat of clean engine oil to new filter gasket. Hand-tighten new filter until gasket contacts mounting surface, then rotate an additional 3/4 turn. Do not overtighten.
   ⚠Oil filter may contain up to 2 quarts of hot oil. Allow to drain into pan before disposal.
3. 3

   Refill engine oil
   Lower vehicle from jack stands. Locate oil fill cap on top of valve cover. Add 12 quarts of Mopar 5W-20 Synthetic Blend engine oil. Install oil fill cap. Start engine and allow to run for 2-3 minutes, monitoring for leaks at drain plug and filter. Shut off engine and wait 5 minutes for oil to settle. Check oil level on dipstick and add remaining oil to bring level to FULL mark.
   ℹ️Final oil level should be checked with engine off and vehicle level after oil has settled.
4. 4

   Replace engine air filter
   Open hood and locate air filter housing on passenger side of engine bay. Release air box clips securing the air filter cover. Remove cover and lift out old air filter element. Inspect housing for debris and clean if necessary. Install new air filter element ensuring proper seating in housing. Reinstall cover and secure all clips.
   Torque spec

   Air Box Clips5 Nm (4 lb-ft)
5. 5

   Drain water from fuel filter separator
   Locate primary fuel filter/water separator mounted on driver side of engine near frame rail. Place drain container under drain valve at bottom of filter housing. Open drain valve by turning counterclockwise and allow water and fuel to drain until clear diesel fuel flows (typically 1/4 to 1/2 cup). Close drain valve securely.
   ⚠Dispose of drained fuel/water mixture according to local environmental regulations. Do not pour on ground or into storm drains.
6. 6

   Replace primary fuel filter
   Place drain container under primary fuel filter housing. Using fuel filter wrench, carefully loosen filter by turning counterclockwise. Fuel will drain as filter is removed. Remove filter and allow housing to drain. Clean filter mounting surface. Fill new filter approximately 3/4 full with clean diesel fuel to minimize air in system. Lubricate filter gasket with diesel fuel. Thread new filter onto housing by hand until gasket contacts base, then tighten an additional 1/2 to 3/4 turn. Do not overtighten.
   ℹ️Pre-filling new fuel filter reduces air in fuel system and shortens priming time.
7. 7

   Replace secondary fuel filter
   Locate secondary fuel filter on top of engine near firewall. Place shop rags around filter housing to catch fuel spillage. Using appropriate wrench, loosen filter housing and remove old filter element. Clean housing thoroughly. Install new secondary fuel filter element according to manufacturer directional arrows. Reinstall housing and secure properly.
   ⚠Secondary fuel filter is located in confined space. Use caution to avoid damaging fuel lines or electrical connections.
8. 8

   Prime fuel system
   Locate hand primer pump on top of primary fuel filter housing (may be built into filter cap or separate pump). Operate primer pump until firm resistance is felt (typically 20-50 strokes), indicating fuel system is primed and free of air. If vehicle is equipped with electric lift pump, cycling ignition key to RUN position (without starting) 3-4 times will also prime system.
   ℹ️Proper priming prevents hard starting and potential air lock in fuel injection system.
9. 9

   Inspect belts and hoses
   With engine cool, visually inspect serpentine belt for cracks, glazing, fraying, or missing ribs. Check belt tension by pressing midway between pulleys (should deflect 1/4 to 1/2 inch with moderate pressure). Inspect all coolant hoses for cracks, bulges, or soft spots. Check hose clamps for tightness. Inspect turbocharger inlet and outlet hoses for damage or loose clamps.
   ℹ️Replace belt if any damage is visible. Cummins diesel accessory belt typically requires replacement every 100,000 miles or signs of wear.
10. 10

    Check fluid levels and inspect for leaks
    Check coolant level in overflow reservoir (should be between MIN and MAX marks when cold). Check power steering fluid level. Inspect brake fluid level in master cylinder reservoir. Check windshield washer fluid and refill if necessary. Start engine and inspect oil drain plug, oil filter, and fuel filters for any signs of leakage. Check exhaust system for leaks while engine is running.

Reassembly

1. Ensure all fill caps are securely installed (oil fill, coolant reservoir, power steering, brake fluid, washer fluid).
2. Verify air filter housing is properly sealed with all clips secured.
3. Confirm no tools or rags are left in engine compartment before closing hood.
4. Dispose of used engine oil, oil filter, air filter, fuel filters, and drained fuel according to local environmental regulations.

Verification

• Start engine and verify oil pressure warning light extinguishes within 2-3 seconds.
• Allow engine to reach operating temperature and verify no leaks from oil drain plug, oil filter, or fuel filters.
• Check that engine idles smoothly without excessive smoke or unusual noises indicating air in fuel system.
• Verify oil level on dipstick shows FULL after engine has been running and oil has settled.
• Test drive vehicle to confirm normal engine operation and no warning lights on instrument cluster.
• Re-check all fluid levels after test drive and top off if necessary.

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