Dodge Caliber - Service Manual - Repair Manual

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DODGE CALIBER - SERVICE MANUAL / REPAIR MANUAL

- English Service Manual to vehicles Dodge Caliber.


CONTENTS:

MAIN WELCOME PAGE

INSTRUCTIONS

PM SERVICE MANUAL

FOREWORD

GROUP TAB LOCATOR

IN-INTRODUCTION
Body Code Plate
Description
Body Code Plate Line 2
Body Code Plate Line 1
If Two Body Code Plates Are Required
Fastener Identification
Description
Fastener Usage
Description
Fastener Usage
Threaded Hole Repair
International Symbols
Description
Metric System
Description
Torque References
Description
Vehicle Identification Number
Description - Vehicle Identification Number
Vehicle Certification Label
Description
E-Mark Label
Description
Veci Label
Description
Manufacturer Plate
Description

0-LUBRICATION & MAINTENANCE
International Symbols
Description
Fluid Types
Description
Engine Oil
Api Certification And License Symbol
Sae Viscosity
Acea Categories
Container Identification
Synthetic Engine Oils
Engine Oil Additives/Supplements
Engine Coolant
Transmission Fluid
Fuel Requirements
Reformulated Gasoline
Gasoline/Oxygenate Blends
Mmt In Gasoline
Sulfur In Gasoline
Materials Added To Fuel
Fuel System Cautions
Brake Fluid
Power Steering Fluid
Fluid Capacities
Specifications - Fluid Capacities
Fluid Fill/Check Locations
Description
Lubrication Points
Description
Maintenance Schedules
Description
Maintenance Schedule
Schedule B
Schedule A
Maintenance Schedules - Gasoline Engines - Export
Schedule A
Schedule B
Hoisting
Standard Procedure - Hoisting
Jump Starting
Standard Procedure - Jump Starting
To Jump Start A Disabled Vehicle:
Towing
Standard Procedure - Towing

2-SUSPENSION
Front Suspension
Description




Warning
Warnings And Cautions
Standard Procedure
Lubrication
Specifications
Front Suspension Fastener Torque
Special Tools
Front Suspension
Hub / Bearing
Description
Diagnosis And Testing
Wheel Bearing And Hub
Removal
Installation
Knuckle
Description
Diagnosis And Testing
Knuckle
Removal
Installation
Seal-Lower Ball Joint
Removal
Installation
Arm-Lower Control
Diagnosis And Testing
Lower Control Arm
Removal
Installation
Bar-Stabilizer
Removal

Installation
Strut Assembly
Description
Operation
Diagnosis And Testing
Strut Assembly
Removal
Disassembly
Assembly
Installation
Rear Suspension
Description
Warning
Warnings And Cautions
Specifications
Rear Suspension Fastener Torque
Arm-Lower Control
Removal
Installation
Arm-Upper Control
Removal
Installation
Link-Toe
Removal
Installation
Link-Trailing
Removal
Installation
Hub / Bearing
Description
Diagnosis And Testing
Hub And Bearing
Removal
All-Wheel-Drive
Front-Wheel-Drive
Installation
All-Wheel-Drive
Front-Wheel-Drive
Bar-Stabilizer
Removal
Installation
Shock Assembly
Description
Diagnosis And Testing
Shock Absorber
Removal
Disassembly
Assembly
Installation
Wheel Alignment
Description
Camber
Cross Camber
Caster
Cross Caster
Toe
Toe-Out On Turns
Dynamic Toe Pattern
Steering Axis Inclination (S.A.I.)
Included Angle (I.A.)
Thrust Angle
Diagnosis And Testing
Suspension And Steering
Standard Procedure
Curb Height Measurement
Wheel Alignment
Pre-Wheel Alignment Inspection
Wheel Alignment Setup
Rear Camber
Front Camber And Caster
Toe
Specifications
Wheel Alignment

3-DIFFERENTIAL & DRIVELINE
Half Shaft-Front
Description
Operation
Diagnosis And Testing
Halfshaft Diagnosis
Vehicle Inspection
Noise And/Or Vibration In Turns
Clunking Noise During Acceleration
Shudder Or Vibration During Acceleration
Vibration At Highway Speeds
Removal

Installation
Specifications
Torque
Special Tools
Halfshaft
Cv Boot-Inner
Removal
Installation
Cv Boot-Outer
Removal
Installation
Half Shaft-Left Rear
Removal
Installation
Half Shaft-Right Rear
Removal
Installation
Shaft-Propeller
Removal
Installation
Module-Rear Driveline
Standard Procedure -
Removal
Disassembly
Assembly
Installation
Specifications -
Special Tools
Seal-Input Flange
Removal
Installation
Seals-Output Flange
Removal
Installation
Clutch-Electronically Controlled-Electrical Diagnostics
Diagnosis And Testing
C1078-Tire Revolutions Range Performance
C1456-Awd Clutch Power Control Circuit Low
C145a-Awd Clutch Return Control Circuit Low
C145d-Awd Clutch Power/Return Control Circuit Open
C145f–Awd System Temporarily Disabled — Overtemperature
C2100–Battery Voltage Low
C2101–Battery Voltage High
C211c-Ignition Run/Start Input Circuit Low
C211d-Ignition Run/Start Input Circuit High
C211e-Battery Supply Voltage Low
C211f–Battery Supply Voltage High
C2208-Awd Ecu Internal
U0001-Can C Bus
U0100-Lost Communication With Ecm/Pcm (Tipm)
U0121-Lost Communication With Abs
U0141 Lost Communication With Fcm (Tipm)
U0401-Implausible Data Received From Ecm/Pcm
U0415-Implausible Data Received From Abs
U0423-Implausible Data Received From Cluster/Ccn
U1120-Lost Wheel Speed Messages
U1415-Implausible/Missing Vehicle Configuration Received
Standard Procedure
Awd - Pre-Diagnostic Troubleshooting Procedure
Awd Control Module Verification Test
Clutch-Electronically Controlled-Service Information
Removal
Installation

4-VEHICLE QUICK REFERENCE
Fluid - Capacities & Recommended
Specifications
Fluids, Lubricants And Genuine Parts
Fuse Locations & Types
Specifications
Integrated Power Module (Ipm)
Maintenance Schedules
Description
Maintenance Schedule
Schedule B
Schedule A
Maintenance Schedules - Gasoline Engines - Export
Schedule A
Schedule B
Replacement Bulbs
Specifications
Replacement Light Bulbs - Interior
Replacement Light Bulbs - Exterior
Trailer Towing
Specifications
Trailer Towing
Common Towing Definitions
Trailer Hitch Classification
Trailer Towing Weights (Maximum Trailer Weight Ratings)
Trailer And Tongue Weight
Towing Requirements
Towing Requirements — Trailer Lights & Wiring
Towing Tips

5-BRAKES
Brakes - Base
Description - Base Brake System
Warning
Caution
Diagnosis And Testing
Base Brake System Diagnosis Charts
Red Brake Warning Indicator
Brake Noise
Other Brake Conditions
Standard Procedure
Base Brake Bleeding
Manual Bleeding
Pressure Bleeding
Specifications
Brake Actuation
Brake Fastener Torque
Special Tools
Base Brake System

Switch-Brake Fluid Level
Description
Removal
Installation
Hydraulic/Mechanical
Description
Disc Brakes
Rear Drum Brakes
Diagnosis And Testing
Drum Brake Automatic Adjuster
Pads-Front Brake
Removal
Cleaning
Inspection
Installation
Pads-Rear Brake
Removal
Cleaning
Inspection
Installation
Shoe And Linings-Rear Drum Brake
Removal
Cleaning
Inspection
Installation
Adjustments
Drum Brake Shoe Adjustment
Caliper-Front Disc Brake
Removal
Disassembly
Cleaning
Inspection
Assembly
Installation
Caliper-Rear Disc Brake
Removal
Disassembly
Cleaning
Inspection
Assembly
Installation
Drum
Diagnosis And Testing
Brake Drum
Standard Procedure
Brake Drum Machining
Removal
Backing Off Shoe Adjustment
Installation
Fluid
Diagnosis And Testing
Brake Fluid Contamination
Standard Procedure0 - 2 Pm
Brake Fluid Level Checking
Specifications
Brake Fluid
Master Cylinder
Description
Operation
Standard Procedure
Master Cylinder Bleeding
Removal
Left-Hand-Drive With Abs
Left-Hand-Drive Without Abs
Disassembly
Assembly
Installation
Left-Hand-Drive With Abs
Left-Hand-Drive Without Abs
Pedal
Removal
Installation
Booster-Power Brake
Description
Diagnosis And Testing
Power Brake Booster
Basic Test
Vacuum Leak Test
Removal
Installation
Valve-Proportioning
Description
Operation
Removal
Installation
Rotor
Diagnosis And Testing
Brake Rotor
Braking Surface Inspection

Rotor Minimum Thickness
Rotor Thickness Variation
Rotor Runout
Standard Procedure
Brake Rotor Machining
Removal
Front Brake Rotor
Rear Brake Rotor
Installation
Front Brake Rotor
Rear Brake Rotor
Specifications
Brake Rotor Limits/Specifications
Tubes/Hoses
Description
Inspection
Plate-Support, Brake Backing
Removal
Installation
Wheel Cylinder - Drum Brake
Removal
Inspection
Installation
Parking Brake
Description
Cable-Parking Brake
Removal

Installation
Lever-Parking Brake
Removal
Installation
Shoe And Linings-Parking Brake
Removal
Installation
Adjustments
Parking Brake Shoe Adjustment
Brakes - Abs Electrical Diagnostics
Diagnosis And Testing
Abs-Intermittent Condition
C1002-Brake Pedal Switch 1 Circuit High
C1007-Brake Fluid Level Circuit Low
C1008-Brake Fluid Level Circuit High
C100a–Left Front Wheel Speed Sensor Circuit
C1011-Left Front Wheel Speed Sensor Signal Erratic Performance
C1014-Left Front Wheel Speed Comparative Performance
C1015–Right Front Wheel Speed Sensor Circuit
C101c-Right Front Wheel Speed Sensor Signal Erratic Performance
C101f-Right Front Wheel Speed Comparative Performance
C1020–Left Rear Wheel Speed Sensor Circuit
C1027-Left Rear Wheel Speed Sensor Signal Erratic Performance
C102a-Left Rear Wheel Speed Comparative Performance
C102b–Right Rear Wheel Speed Sensor Circuit
C1032-Right Rear Wheel Speed Sensor Signal Erratic Performance
C1035-Right Rear Wheel Speed Comparative Performance
C1038–Rear Wheel Speed Sensor Circuit Low
C1039–Rear Wheel Speed Sensor Circuit High
C1041-Left Front Tone Wheel Performance
C1042-Right Front Tone Wheel Performance
C1043-Left Rear Tone Wheel Performance
C1044-Right Rear Tone Wheel Performance
C1046–Left Front Wheel Pressure Phase Monitoring
C1047–Right Front Wheel Pressure Phase Monitoring
C1048–Left Rear Wheel Pressure Phase Monitoring
C1049–Right Rear Wheel Pressure Phase Monitoring
C1073-Abs Pump Motor Control Circuit
C1078-Tire Revolutions Range Performance
C107c–Brake Pedal Switch 1/2 Stuck
C107d–Brake Pedal Switch 1/2 Correlation
C1210–G Sensor Input Circuit Performance
C1219–Steering Angle Sensor Erratic Performance
C121a–Steering Angle Sensor Not Initialized
C121c-Torque Request Signal Denied
C121d–Brake Pressure Sensor Circuit
C121e-Brake Pressure Sensor Comparative Performance
C1221-Brake Pressure Sensor/Accel Pedal Position Sensor Correlation
C1231–Drive Test: Steering Angle Sensor
C1232–Drive Test: Pressure Sensor
C1234–Drive Test: Sensor Cluster Installation
C1238-Drive Test: Unsuccessful
C123a–Esp System Sensors Calibration
C123b–Esp System Control Too Long
C123c–Dynamics Sensor Mounting/Installation Performance
C123f–Steering Angle Sensor Comparative Performance
C1240–Steering Angle Sensor Overtravel Performance
C1242–G Sensor Input Signal Performance
C1243–G Sensor Not Initialized
C2100–Battery Voltage Low
C2111–Sensor Supply 1 Voltage Circuit Low
C2112–Sensor Supply 1 Voltage Circuit High
C2114–Dynamics Sensor Supply Voltage Low
C2115–Dynamics Sensor Supply Voltage High
C2116–Abs Pump Motor Supply Low Voltage
C2200–Anti-Lock Brake Module Internal
C2204–Dynamics Sensor Internal
C2205–Steering Angle Sensor Internal
C2206–Vehicle Configuration Mismatch
U0002–Can C Bus Off Performance
U0100–Lost Communication With Ecm/Pcm
U0101–Lost Communication With Tcm
U0114-Lost Communication With Final Drive Module (Tipm)
U0125–Lost Communication With Dynamics Sensor
U0141-Lost Communication With Front Control Module (Tipm)
U0146–Lost Communication With Central Gateway
U0401–Implausible Data Received From Ecm/Pcm
U1003–Esp Can C Bus Performance
U1104–Can C Bus Crc Performance
U140e–Implausible Vehicle Configuration Data Received
U1501–Implausible Message Data Length Received From Ecm/Pcm
U1502–Implausible Message Data Length Received From Tcm
U1503–Implausible Message Data Length Received From Tipm (Tipm)
Standard Procedure
Abs Verification Test
Brakes - Abs Service Information
Description
Antilock Brake System
Abs
All-Speed Traction Control
Electronic Variable Brake Proportioning
Operation
Antilock Brake System
Abs
All-Speed Traction Control
Electronic Variable Brake Proportioning
Caution
Diagnosis And Testing
Inspection And Road Test
Standard Procedure
Antilock Brake System Bleeding
Bleeding
Specifications
Abs Fastener Torque
Sensor-Dynamics (Esp)
Description
Removal

Installation
Sensor-Front Wheel Speed
Description
Operation
Removal
Installation
Sensor-Rear Wheel Speed
Description
Operation
Removal
All-Wheel-Drive
Front-Wheel-Drive
Installation
All-Wheel-Drive
Front-Wheel-Drive

Switch-Esp
Description
Removal
Installation
Hydraulic Control Unit (Hcu)
Description
Valves And Solenoids
Brake Fluid Accumulators
Pump/Motor
Removal
Installation
Integrated Control Unit (Icu)
Description
Operation
Removal

Gas Engine
Diesel Engine
Disassembly
Assembly
Installation
Gas Engine
Diesel Engine

6-CLUTCH
Clutch
Description
Fluid
Operation
Diagnosis And Testing
Clutch System
Clutch Chatter Complaints
Drive Plate Misalignment

Clash-Into-Reverse Complaints
Standard Procedure
Gravity Bleeding Clutch Hydraulic Circuit
Power Bleeding Clutch Hydraulic Circuit
Specifications
Clutch/Hydraulics/Pedals
Special Tools
Hydraulic Clutch
Plate-Clutch Disc And Pressure
Removal
Diesel
Gas
Installation
Diesel
Gas
Flywheel
Operation
Removal
Installation
Cylinder-Master-Lhd
Description
Operation
Removal
Installation
Cylinder-Master-Rhd
Description
Operation
Removal
Installation
Clutch-Modular
Description
Operation
Removal
Inspection
Oil Contamination
Grease Contamination
Road Splash/Water Contamination
Installation
Cylinder-Slave
Description
Removal
Removal
Installation

7-COOLING
Cooling
Description
Operation
Warning
Cooling System Warnings
Diagnosis And Testing
Diagnosis And Testing - Cooling System Aeration
Diagnosis And Testing - Cooling System Deaeration
Diagnosis And Testing - Cooling System Flow Check
Cooling System Leak Testing
Cooling System
Standard Procedure
Routine Coolant Level Check
Draining Cooling System
Filling Cooling System
Cooling System Cleaning/Reverse Flushing
Cleaning
Reverse Flushing
Reverse Flushing Radiator
Reverse Flushing Engine
Chemical Cleaning
Inspection
Specifications
Torque
Special Tools
Cooling System
Belt Accessory Drive
Accessory Drive Belt
Description
Diagnosis And Testing
Accessory Drive Belt
Visual Diagnosis
Noise Diagnosis
Removal
World Engine
Cleaning
Installation
World Engine
Accessory Drive Belt Tensioner
Description
Removal
World Engine
Installation
World Engine
Idler Pulley
Removal
Installation
Engine
Coolant
Description
Engine Coolant
Ethylene-Glycol Mixtures
Propylene-Glycol Mixtures
Hoat Coolant
Coolant Performance
Coolant Selection And Additives
Operation
Diagnosis And Testing
Coolant Concentration Testing
Clamps Hose
Description
Container Coolant Recovery
Description
World Engine
Operation - World Engine
Removal - World Engine
Installation - World Engine
Heater Engine Block
Description
Operation
Diagnosis And Testing
Engine Block Heater Testing
Removal
Installation
Sensor Engine Coolant Temp
Description

World Engine
Operation
Removal
Cylinder Head Mounted
Coolant Adapter Mounted
Installation
Coolant Adapter Mounted
Cylinder Head Mounted
Thermostat Engine Coolant
Description
Operation
Diagnosis And Testing - Engine Coolant Thermostat
Removal
Primary Thermostat
Secondary Thermostat
Installation
Primary Thermostat
Secondary Thermostat0 - 4 Pm
Cap Radiator Pressure
Description
Gas Engines
Operation
Gas Engines
Diagnosis And Testing
Diagnosis And Testing - Cooling System Pressure Cap Testing
Diagnosis And Testing - Cooling System Pressure Relief Testing
Cleaning
Inspection
Draincock Radiator
Removal
Installation
Fan-Radiator
Description
Operation
Diagnosis And Testing
Radiator Fan
Removal - World Engine
Installation - World Engine
Radiator
Description
Operation
Removal
Cleaning
Inspection
Installation
Pump-Water
Description
World Engine
Diagnosis And Testing
Water Pump
Removal - World Engine
Inspection
Installation - World Engine
Inlet Tubewater Pump-World Engine
Removal
Installation
Transmission
Transmission
Standard Procedure - Transmission Cooler Line Quick Connect Fitting Disassembly/Assembly
Disconnect
Connect
Cooler Automatic Transmission
Description
Removal
Cleaning
Inspection
Installation

8A-AUDIO/VIDEO
Audio/Video Systems- Electrical Diagnosis
Diagnosis And Testing
B1401-Front Left Audio Speaker Output Circuit Low
B1402-Front Left Audio Speaker Output Circuit High
B1403-Front Left Audio Speaker Output Circuit Open
B1405-Front Right Audio Speaker Output Circuit Low
B1406-Front Right Audio Speaker Output Circuit High
B1407-Front Right Audio Speaker Output Circuit Open
B1409-Rear Left Audio Speaker Output Circuit Low
B140a-Rear Left Audio Speaker Output Circuit High
B140b-Rear Left Audio Speaker Output Circuit Open
B140d-Rear Right Audio Speaker Output Circuit Low
B140e-Rear Right Audio Speaker Output Circuit High
B140f-Rear Right Audio Speaker Output Circuit Open
B1421-Audio Cd Read Error/Inoperable Disc
B142f-Satellite Radio Antenna Not Connected
B1460-Channel 1 Audio Speaker Output Circuit Performance
B1461-Channel 1 Audio Speaker Output Circuit Low
B1462-Channel 1 Audio Speaker Output Circuit High
B1463-Channel 1 Audio Speaker Output Circuit Open
B1464-Channel 1 Audio Speaker Output Circuit Shorted Together
B1465-Channel 2 Audio Speaker Output Circuit Performance
B1466-Channel 2 Audio Speaker Output Circuit Low
B1467-Channel 2 Audio Speaker Output Circuit High
B1468-Channel 2 Audio Speaker Output Circuit Open
B1469-Channel 2 Audio Speaker Output Circuit Shorted Together
B146a-Channel 3 Audio Speaker Output Circuit Performance
B146b-Channel 3 Audio Speaker Output Circuit Low
B146c-Channel 3 Audio Speaker Output Circuit High
B146d-Channel 3 Audio Speaker Output Circuit Open
B146e-Channel 3 Audio Speaker Output Circuit Shorted Together
B146f-Channel 4 Audio Speaker Output Circuit Performance
B1470-Channel 4 Audio Speaker Output Circuit Low
B1471-Channel 4 Audio Speaker Output Circuit High
B1472-Channel 4 Audio Speaker Output Circuit Open
B1473-Channel 4 Audio Speaker Output Circuit Shorted Together
B1474-Channel 5 Audio Speaker Output Circuit Performance
B1475-Channel 5 Audio Speaker Output Circuit Low
B1476-Channel 5 Audio Speaker Output Circuit High
B1477-Channel 5 Audio Speaker Output Circuit Open
B1478-Channel 5 Audio Speaker Output Circuit Shorted Together

B1479-Channel 6 Audio Speaker Output Circuit Performance
B147a-Channel 6 Audio Speaker Output Circuit Low
B147b-Channel 6 Audio Speaker Output Circuit High
B147c-Channel 6 Audio Speaker Output Circuit Open
B147d-Channel 6 Audio Speaker Output Circuit Shorted Together
B2222-Satellite Radio Receiver Internal
U0019–Can B Bus
U0020-Can B Bus Off Performance
U0184-Lost Communication With Radio
U0186-Lost Communication With Audio Amplifier
U0195-Lost Communication With Sdar
U0197-Lost Comminication With Hands Free Module
U0199-Lost Comminication With Drivers Door Module
U0200-Lost Comminication With Passenger Door Module
U0151-Lost Comminication With Occupant Restraint Controller
U0154-Lost Comminication With Occupant Classification Module
Audio
Description
Operation
Diagnosis And Testing - Audio
Amplifier
Description
Operation
Removal
Installation
Antenna Body And Cable
Description – Fixed Mast Antenna
Description – Roof Mounted Antenna
Operation
Diagnosis And Testing - Antenna Body And Cable

AND MORE....