Tune-Up - Minor

Routine minor tune-up service for the 5.9L Cummins diesel engine including fuel filter replacement, air filter service, and system inspections.

Warnings

Tools required

Parts

• Fuel filter cartridge × 1 — Mopar 68157291AA or equivalent
• Engine air filter × 1 — Use OEM specification
• Fuel water separator drain valve (if damaged) × 1 — Use OEM specification
• Air filter housing clamps (if damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level ground and engage parking brake
2. Allow engine to cool to ambient temperature if recently operated
3. Open hood and secure with prop rod
4. Gather all tools and replacement parts within easy reach
5. Place drain pan and shop towels under fuel filter housing area

Procedure

1. 1

   Drain fuel water separator
   Locate the fuel water separator drain valve on the bottom of the fuel filter housing on the driver side of the engine. Attach drain hose if available, or position drain pan directly beneath valve. Open drain valve by turning counterclockwise and allow water and contaminants to drain until clean fuel flows (approximately 1/4 to 1/2 cup). Close valve by turning clockwise until snug.
2. 2

   Remove fuel filter assembly
   Locate the fuel filter canister on the driver side of the engine block. Use fuel filter wrench or strap wrench to turn the black plastic filter canister counterclockwise to loosen. Continue unscrewing by hand once loose. Tilt filter slightly to minimize spillage and place in drain pan. Expect approximately 1-2 cups of diesel fuel to drain from filter.
3. 3

   Clean filter housing and inspect seals
   Wipe the filter mounting base on the engine block clean with shop towels, paying particular attention to the sealing surface. Inspect the mounting surface for damage or debris. Remove the old O-ring seal from the filter housing base if it did not come off with the old filter. Verify the new fuel filter includes a new O-ring seal.
4. 4

   Prepare and install new fuel filter
   Remove protective cap from new fuel filter if present. Lightly coat the O-ring seal on the new filter with clean diesel fuel or clean engine oil. Thread the new filter onto the housing base by hand, turning clockwise. Once the O-ring makes contact with the base, continue turning 3/4 to 1 full turn by hand only. Do not use filter wrench to tighten.
5. 5

   Prime fuel system
   Locate the hand primer pump on top of the fuel filter housing. Operate the primer pump repeatedly until it becomes firm and resistance is felt, indicating the filter is full and system is primed. Check around the filter base for fuel leaks while priming.
6. 6

   Remove engine air filter
   Locate the air filter housing in the engine bay (typically passenger side). Release the clamps securing the air filter housing cover (typically 4-6 spring clamps or screw clamps). Carefully lift the housing cover away and set aside. Remove the old air filter element from the housing, noting its orientation.
7. 7

   Clean air filter housing
   Use a clean dry cloth or shop towels to wipe out the interior of the air filter housing, removing any dirt, debris, or dust. Inspect the housing for cracks or damage. Check the air intake tube and connections for holes, cracks, or loose clamps. Clean the sealing surface where the housing cover mounts.
8. 8

   Install new air filter
   Place the new air filter element into the housing in the same orientation as the old filter was installed, ensuring it seats properly in the housing bottom. Verify the filter element sealing edges are properly positioned and not folded over. Replace the housing cover and secure all clamps evenly, ensuring a proper seal.
9. 9

   Inspect drive belts
   With a flashlight, visually inspect the serpentine belt for cracks, glazing, fraying, or missing ribs. This engine uses an automatic spring-loaded belt tensioner; verify the tensioner arm operates freely and is within its wear-indicator range rather than measuring manual deflection. Look for proper belt alignment on all pulleys. Note any issues for future service.
10. 10

    Inspect fluid levels and hoses
    Check engine oil level using dipstick and verify it is within the safe range. Inspect coolant level in the overflow reservoir (should be between MIN and MAX marks when cold). Visually inspect all visible hoses for cracks, bulging, or leaks. Check power steering fluid level. Note any deficiencies for correction.

Reassembly

1. Ensure all air filter housing clamps are properly secured
2. Verify fuel filter is hand-tight and not leaking
3. Remove tools and drain pan from engine bay
4. Wipe up any spilled diesel fuel with shop towels and dispose of properly

Verification

• Start the engine and allow it to idle for 2-3 minutes
• Observe the fuel filter area for any fuel leaks while engine is running
• Check that the 'Water in Fuel' warning light (if equipped) is not illuminated after startup
• Listen for normal engine operation with no unusual sounds or rough running
• Verify no air filter housing whistling or unusual intake noises
• Take a short test drive and verify normal engine performance and throttle response

Related trouble codes on this vehicle

Codes that commonly send this job to the bay — tap one for symptoms, causes, and diagnostic steps.

Chasing one of these codes and not sure which part is guilty? Ask a master mechanic about YOUR car →

More procedures for this vehicle